Shape Of Workpiece Research Articles

Geometric physically-based simulation of microfinishing: tool design impact on workpiece shape

Geometric physically-based simulation of microfinishing: tool design impact on workpiece shape

Choosing the Design of a Radial-Shear Rolling Mill for Obtaining a Screw Profile

The purpose of this work is a comparative analysis of the workpiece shape, and parameters of the stress-strain state during deformation on two radial-shear rolling mills with different roll configurations to determine the most suitable scheme for obtaining a screw reinforcement profile. During the FEM simulation of the radial-shear rolling process in the DEFORM program, a comparison of the workpiece shape change after rolling, equivalent strain, damage index, and Lode–Nadai index was carried out. Steel 10 (analogue of AISI 1010) was chosen as material workpiece. The analysis of the obtained data revealed that the most rational choice for the implementation of the reinforcement profile production process is the radial-shear rolling mill RSR 10-30. Subsequent modeling of the combined process of radial-shear rolling and twisting in a screw matrix showed that when using rolls of RSR 10-30 mill, the screw profile of the workpiece is formed successfully, whereas using rolls of the SVP-08 mill, the formation of a screw profile is impossible due to jamming due to an irregular cross-section shape. A laboratory experiment confirmed the possibility of forming a screw reinforcement profile at RSR 10-30 mill, and an assessment of the geometric parameters of the final workpiece showed full compliance with the dimensions of the profiles obtained during modeling and experiment.

A generalisable tool path planning strategy for free-form sheet metal stamping through deep reinforcement and supervised learning

AbstractDue to the high cost of specially customised presses and dies and the advance of machine learning technology, there is some emerging research attempting free-form sheet metal stamping processes which use several common tools to produce products of various shapes. However, tool path planning strategies for the free forming process, such as reinforcement learning technique, derived from previous path planning experience are not generalisable for an arbitrary new sheet metal workpiece. Thus, in this paper, a generalisable tool path planning strategy is proposed for the first time to realise the tool path prediction for an arbitrary sheet metal part in 2-D space with no metal forming knowledge in prior, through deep reinforcement (implemented with 2 heuristics) and supervised learning technologies. Conferred by deep learning, the tool path planning process is corroborated to have self-learning characteristics. This method has been instantiated and verified by a successful application to a case study, of which the workpiece shape deformed by the predicted tool path has been compared with its target shape. The proposed method significantly improves the generalisation of tool path planning of free-form sheet metal stamping process, compared to strategies using pure reinforcement learning technologies. The successful instantiation of this method also implies the potential of the development of intelligent free-form sheet metal stamping process.

Effect of warm forming process parameters on 42CrMo4 skew rolled bar mechanical properties and microstructure

Skew rolling is a manufacturing process in which two or three rolls are used to reduce the diameter or modify the shape of a cylindrical workpiece, which is used to manufacture mechanical components such as shafts, rods or balls. Hot conditions are used to overcome limitations related to material ductility, residual stress and machine capacity. In this paper, the warm skew rolling (WSR) process of 42CrMo4 rods is modeled by the finite element method. The effects of forming parameters, namely initial temperature and roll rotational velocity, on the material strain rate, thermal properties, microstructure and hardness were analyzed. Simulation results were validated by experimental process data, while hardness tests and SEM-EBSD microscopy were used to assess mechanical properties and microstructure, respectively. The WSR resulting microstructure is different from the normalized ferritic–pearlitic initial one. The degree of spheroidization (DoS) of cementite increases with temperature. The maximum DoS of 86.5% occurs at the initial temperature of 750 °C, leading to the highest material softening. Rolling from lower temperatures favors grain fragmentation and the achievement of incomplete spheroidization, which, in combination with the highest proportion of high-angle boundaries, contributes to a higher hardness of the rods with respect to those rolled at higher temperatures. The highest reduction in hardness takes place at 750 °C and 30 rpm, leading to 209.4 HV1 (30.7% reduction) and 194.1 HV1 (35.7% reduction) in the near-surface and internal regions, respectively. The driving factor is the transformation of cementite precipitates into a spheroidal form characterized by the greatest degree of dispersion.

The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining.

Deterministic polishing based on jet electrochemical machining (Jet-ECM) is a stress-free machining method for low-rigidity and ultra-precision workpieces. The nozzle is equivalent to a special tool in deterministic polishing, and the workpiece material is removed using the mechanism of electrochemical dissolution at the position where the nozzle passes. By precisely regulating the nozzle's movement speed and dwell time, the quantity of material removed from the workpiece at a designated position can be finely adjusted. With this mechanism, the improvement of the workpiece shape accuracy can be achieved by planning the nozzle trajectory and nozzle movement speed. However, due to the positioning errors of the polishing device, the actual position of the nozzle may deviate from the theoretical position, resulting in errors in material removal amount, which affects the accuracy and stability of the polishing process. This study established a mathematical model to analyze the influence of nozzle positioning errors in deterministic polishing based on Jet-ECM. This model has been used to design a specific deterministic polishing device based on Jet-ECM. With the proposed deterministic polishing device, the surface shape of the workpiece is converged. The surface peak-to-valley (PV) value of the φ 50 mm workpiece (valid dimensions = 90% of the central region) indicated that the shape error of the surface was reduced from 2.67 μm to 1.24 μm in 34 min. The power spectral density (PSD) method was used to evaluate the height distribution and height characteristics of the workpiece surface. The results show that the low frequency spatial error is reduced significantly after processing. This study improves the accuracy of the stress-free deterministic polishing methods and further expands the use of deterministic polishing in industry.

Moving Object Detection Method Based on the Fusion of Online Moving Window Robust Principal Component Analysis and Frame Difference Method

The accuracy of moving object detection has a great impact on the accuracy of extracting the shape center coordinates of moving workpieces. The classic inter-frame difference method has "cavity" and "double shadow" issues for workpieces with comparable internal colors. In order to solve this problem, a moving object detection algorithm combining the three-frame difference method and Online Moving Window Robust Principal Component Analysis (OMWRPCA) is proposed. By using the OMWRPCA to extract the background image in the current frame and comparing it to the previous and current frames, the "cavity" and "double shadow" problems are avoided as well as the effects of background pixels. This paper presents a case study of a visual sorting experiment bench in an "intelligent manufacturing production demonstration line". The experiments show that the workpiece shape center coordinates obtained by the improved moving object detection algorithm are closer to the actual value than those obtained by the traditional algorithm, and the F-measure scores are above 0.8, which are more accurate than the other two algorithms. It is compared with the traditional algorithm of the frame difference method and the Online Mixture of Gaussian Matrix Factorization (OMoGMF).

Study on the Material Models of the Forming Limit Curves Development for Predicting a Fracture Behavior of AA5754-O in Automotive Parts

The forming limit curve (FLC) is commonly used to predict the formability behavior of sheet metal after the forming process. In this research, the forming limit curve generated from the Materials Model was applied to analyze and predict the fracture behavior of the fuel tank workpiece, a motorcycle part made of AA5754-O material, using the deep drawing process simulated by the finite element method. The research involved a comparison with actual cracks that occur in the automotive industry after molding. To determine the mechanical properties of the AA5754-O material for use in the forming limit curve, a specimen with a thickness of 1.5 mm was subjected to a tensile strength test, providing the necessary input for the mechanical properties in the forming limit curve based on the Keeler-Beizer equation. The forming limit curve is a correlation graph between major strain and minor strain. When the FLC is created from the Materials Model, it is utilized in conjunction with deep drawing drag simulation in the PAM-STAMP program to predict the fracture point. The accuracy of the mathematically generated FLC in predicting fracture behavior was verified after the deep drawing process. The study found that the FLC based on the Keeler-Beizer equation can accurately predict the cracking behavior of AA5754-O sheet metal, enabling identification of the fracture location during the deep drawing process. One advantage of creating the FLC from the material models is its compatibility with the same material but with different workpiece shapes, allowing its use in conjunction with molding simulations using various programs. This approach saves costs associated with testing to obtain the FLC.

Experimental study on the influence of workpiece shape on discharge gap and burr in LS-WEDM and the preparation of microelectrode array with specific size

Experimental study on the influence of workpiece shape on discharge gap and burr in LS-WEDM and the preparation of microelectrode array with specific size

Methodology for the automated digitization and probing of workpieces in a machining center by combining optical and tactile measurements

With respect to the digitization of production processes, there is an increased demand for automated machining processes. The shape of the workpieces can be complex, e. g., when designing milling processes for functional surfaces of additively manufactured parts. The determination of the workpiece coordinate system can be challenging, especially for freeform surfaces and a high initial surface roughness. In this paper, a methodology for the automated digitization of workpieces in a machining center is presented. An integrated camera system is combined with tactile measurements in order to determine the workpiece shape and the clamping situation.

Оценка схемы многоканального углового прессования прутков и возможности ее применения на практике

Introduction. Deformation of low-plastic materials requires a high degree of compressive stress. This requirement is implemented, for example, in the process of equal channel angular pressing (ECAP). However, the products obtained by the ECAP method have a cross-section identical to the initial blank, which is one of the disadvantages of this method. The method of nonequal channel angular pressing (NECAP), in contrast to ECAP, makes it possible to change the shape of the initial blank towards closer to the shape of the finished product. However, the well-known NECAP device allows obtaining products only in the form of a thin strip of rectangular cross-section. Well-known devices for multichannel pressing of non-angular type also have a disadvantage — it is implemented only on horizontal type presses, where it is possible to receive long products on the workshop areas. The aim of the work is the evaluation of the bars’ multichannel angular pressing scheme, combining a change in the shape of the initial workpiece in cross-section, as well as the accumulation of a high level of strain during deformation. Research methods: finite element modeling using the DEFORM software module. Results and discussion. The paper considers the scheme of the angular pressing process with the use of a device that allows, for example, to obtain magnesium bars with a diameter of d = 4.1 mm with the number of matrix channels n = 3 from a blank of round cross-section. The container of this device in its lower part has a rectangular groove where the matrix is inserted. Modeling of the process under study using a matrix with the axes of its channels located in the plane of the orthogonal axis of the container and, in the first variant, along the axis of a rectangular groove, and in the second variant, along the radius of the container, allowed us to estimate the distribution of the average stress. It is established that the metal of the blank in both variants of the deformation process is affected by compression stresses at a high level (1,600 MPa). The assessment of the degree of deformation of the pressed bars allowed us to find out that at the initial stage of both process variants, the maximum strain degree can reach 2.6, and at the steady stage it reaches 5.0. It is established that in the case of the first variant of the matrix, the strain level along the length of the bars is lower than when using the second variant of the matrix. The difference reaches 20 %. By evaluating the distribution of the strain degree in the cross section of the pressed bars near the deformation site, it was found that in the case of the first variant of the matrix, the pressed bars of the first and third channels have an uneven dimensions, and the greater value of the strain degree is on the peripheral part of the rods from the side bordering the central bar. This difference in the strain degree reaches 20 %. When placing the second version of the matrix, this unevenness decreases to 12 %. Thus, in the case of using a matrix with the arrangement of the channel axes along the radius of the container, the strain degree is distributed more evenly compared to the strain degree when using a matrix with the arrangement of the channel axes along the axis of a rectangular groove.

Effect of pad surface morphology on the surface shape of the lapped workpiece

Double-sided lapping is currently the mainstream manufacturing method for obtaining plane-parallel optical workpieces with high surface shape accuracy, and the fixed abrasive lapping pad is the main machining tool. However, the effect of pad surface morphology on the workpiece surface shape has rarely been studied, and its formation mechanism has not yet been revealed. In this paper, based on probabilistic statistics and contact mechanics, an analytical model that takes into account the pad surface morphology for predicting the workpiece surface shape evolution is developed. Notably, this model considers the cross-scale relationship between the formation of lapped surface shape and the scratching process of a single abrasive grain in material removal for the first time. Furthermore, the real-time dynamical contact relationship between the workpieces and the measured actual pad surface morphology is also considered. The surface shape and peak-to-valley value of the workpiece under different parameters were simulated and analyzed, and the influence mechanism of the local profile and macro shape of the lapping pad on the lapped workpiece surface shape are clarified. Moreover, the double-sided lapping trial experiments were performed to validate the theoretical model, and the experimental results demonstrated good agreement with the simulation results. The maximum error of the surface shape evolution prediction model is less than 14.6 %. This result verifies the correctness and validity of the established model. This work not only provides new ideas for controlling the workpiece surface but also forms the theoretical basis for understanding the double-sided lapping process.

3D winding path modeling of overwrapped pressure vessels with novel mesh-based directional projection and normal adaptive convex helix algorithms

Filament winding is a technique that precisely places continuous fibers along a preset path on a rotating mandrel. However, traditional 2D winding paths based on the original mandrel surface ignore the effect of thickness stacking on doffing points. To physically simulate the build-up of tows on the mandrel, a novel numerical method, including the mesh-based directional projection (MDP) and normal adaptive convex helix (NACH) algorithms, is proposed. The MDP algorithm is employed to sort out tow overlaps in the thickness direction, and is 200 times more efficient than the existing algorithms, such as the backward search algorithm. Subsequently, the “cliffs” generated in the overlap removal process are smoothed by the NACH algorithm. Furthermore, the advantages of these two algorithms in terms of efficiency, reliability, and universality are discussed in detail. In summary, a method for developing a physical-based 3D path and ever-updating workpiece contour of pressure vessels is proposed, which serves as an essential reference for high-precision winding and workpiece shape optimization.

Exact forming for additive manufacturing using an irregular element-based compensating approach: Simulation, experiment, and detection

During the additive manufacturing, the shape of workpieces is influenced by printing parameters. To achieve the desired shape of the workpiece, an optimization algorithm is often used to determine an effective combination of printing parameters. Although multiparameter optimization can improve structure quality, they are very time-consuming. In this article, we propose a timesaving irregular element-based compensating approach, which allows a more precise fitting of the geometric boundaries without needing additional computing resources. Finally, we demonstrate that the proposed approach can accurately shape the workpiece to fulfill the expected computer-aided design geometry by experimental verification and error comparison analysis.

Effect of Contact Pressure on Strain Distribution during Compression-Type Bulk Forming Processes.

Inhomogeneity of the material properties of workpieces developed during compression-type bulk forming processes (CBFPs) is an important issue. The effect of contact pressure on the workpiece surface on the strain inhomogeneity in the workpiece was investigated to understand and reduce the formation of strain inhomogeneity during CBFPs. Workpieces fabricated via rod caliber rolling, rod flat rolling, plate flat rolling, and rod compression were analyzed and compared. The extent of strain inhomogeneity in a workpiece differs with the forming process, because the occurrence of macroscopic shear bands (MSBs) is dependent on the workpiece shape and tool design. A flat-rolled rod exhibits the maximum strain inhomogeneity, whereas a flat-rolled plate shows the minimum strain inhomogeneity. The occurrence of MSBs was influenced by the distribution of the normal contact pressure or compression stress. The MSBs were stronger when the contact pressure was higher in the edge region of the surface. For example, the flat-rolled plate exhibited weak MSBs due to the relatively uniform or higher contact pressure on the central region. In contrast, strong MSBs appeared in the flat-rolled rod and compressed rod, because the contact pressure in the edge region of these two processes was high. Thus, the strain inhomogeneity in a workpiece fabricated via CBFPs can be reduced by controlling the contact pressure distribution on the workpiece surface.

An Overview of the Latest Progress in Internal Surface Finishing of the Additively Manufactured Metallic Components.

Fast progress in near-net-shape production of parts has attracted vast interest in internal surface finishing. Interest in designing a modern finishing machine to cover the different shapes of workpieces with different materials has risen recently, and the current state of technology cannot satisfy the high requirements for finishing internal channels in metal-additive-manufactured parts. Therefore, in this work, an effort has been made to close the current gaps. This literature review aims to trace the development of different non-traditional internal surface finishing methods. For this reason, attention is focused on the working principles, capabilities, and limitations of the most applicable processes, such as internal magnetic abrasive finishing, abrasive flow machining, fluidized bed machining, cavitation abrasive finishing, and electrochemical machining. Thereafter, a comparison is presented based on which models were surveyed in detail, with particular attention to their specifications and methods. The assessment is measured by seven key features, with two selected methods deciding their value for a proper hybrid machine.

Vibration and deformation suppression in mirror milling of thin-walled workpiece through a magnetic follow-up support fixture

Large thin-walled workpieces have large deformation and vibration during end milling due to their weak rigidity, which can lead to degradation of the surface quality of workpiece. To this end, this paper proposes a new method to suppress vibration and deformation during mirror milling of thin-walled workpieces by using a magnetic follow-up support fixture. The main idea is to design a fixture that can clamp around the milling area of the workpiece in real time, follow the tool motion and continuously provide a controlled air pressure force to the opposite side of the milling area without providing the mirroring support fixture that occupies a large space to the opposite side of workpiece. First, to accurately characterize the motion of the fixture, a mathematical model of the axial magnetic force considering the lateral offset is developed. On this basis, to efficiently investigate the capability of the fixture in improving the dynamic characteristics and dynamic response of workpiece, the finite element method (FEM) is used to analyze the frequency response functions (FRF) and the mode shapes of workpiece under the action of the fixture. Then, the vibration amplitude and deformation of workpiece on the milling path are simulated and studied by considering the variation of the air pressure and the position of the fixture. Finally, the prototype of the fixture is developed and then the effectiveness and feasibility of the proposed method are verified under the experimental tests with different machining parameters.

Study on the control method of flatness of thin-walled parts milled from 7075 aluminum alloy based on ice-fixation

Investigation of a new process and method to control the planarity of thin-walled parts can provide an important theoretical and application foundation for the high-precision, high-quality fabrication of thin-walled components in aerospace and other areas. A planarity control method based on ice fixation for the milling of thin-walled parts is proposed for thin-walled aluminum alloy 7075 flat parts. The heart of the method is the application of a low temperature of about −5 °C to a flat thin-walled part using a freezing tray to hold the workpiece in place in order to control the flatness of the thin wall face grinding process. Investigation of the influence of the machining process and workpiece shape parameters on the machining flatness of thin-walled parts was conducted based on the practicality and efficiency of the method. Experimental results demonstrate that: compared to traditional milling (non-ice fixation), this method of fixing the ice can significantly improve the milling flatness of thin-walled parts, with the reduction of flatness ranging from 16.4% to 60.0%; however, the reduction of flatness is accompanied by the phenomenon of increasing milling force, with the mean increase in milling strength ranging between 5.8% and 40.3%; the flatness of the machining process decreases with increasing workpiece thickness (15.6%–65.0%) and increases with an increasing aspect ratio of the workpieces (17.4%–48.7%). The orthogonal test results show that the best-machined flatness can be achieved at large spindle speed, high feed rate, and low cutting depth working conditions, i.e. spindle speed 3000r·min−1, feed rate 350 mm·min−1, and cutting depth 0.01 mm.

Statistical analysis and suppression of vibration frequency bifurcation in diamond turning of Al 6061 mirror

In diamond turning of metal mirrors, the reflectivity heavily relies on the mirror surface roughness, and the vibration of machine tool is one of the crucial factors affecting the mirror surface roughness. Previous articles mostly focused on the vibration of the spindle, but in the process of spherical surface machining, the influence of Z-direction moving parts can not be ignored. In this work, by using the transfer matrix and prediction-correction method, a dynamics model is developed to determine the different order vibration frequencies for Z-direction moving parts. The vibration patterns are further revealed in terms of the state vector of each order component with consideration of the external forces, e.g. dynamic cutting forces and linear motor thrust harmonics. As the machining parameters increase, the vibration tends to become instability, and the bifurcation of vibration frequency appears. The sensitivity analysis results firstly show that the cutting depth and workpiece surface slope are the most important factors influencing the vibration frequency bifurcation phenomenon. The probability density distribution of the vibration frequency bifurcation is firstly established as a function of the workpiece shape by stochastic big data simulations, and an adaptive optimization algorithm of interpolation point position is established. Finally, the correctness of the model is verified by experiments, and the relative error is kept below 10%. Through the new interpolation point planning algorithm, the vibration is reduced by more than 50%. Our findings are of significant importance for improving the spherical/aspherical surface reflectivity of metal mirrors.

Construction of a flat workpiece for manufacturing a turn of the right helicoid

In technology, a common helical surface is a right closed helicoid (auger). It is formed by a helical movement of a horizontal segment, provided that the axis of the auger crosses at one of its ends. The formation of the surface of an open helicoid is similar but the segment must intersect the axis and be located at a constant distance from it. It is known from differential geometry that the helical surface can be transformed by bending to the surface of rotation. This fact is taken as the basis for calculating the geometric shape of a flat workpiece. The surface of the open helicoid is non-disjointed, so the shape of the workpiece must be found in such a way as to minimize plastic deformations during surface formation. Parametric equations of continuous flexion of the turn of an open helicoid into the section of a single-cavity hyperboloid of rotation have been derived. Continuous bending can be represented as a gradual deformation of the turn while reducing its step. The meridian of hyperboloid rotation is the corresponding area of hyperbola. The hyperboloid section is proposed to be approximated by the surface of the truncated cone. This approximation will be more accurate in the area of the hyperbole where it asymptotically approaches the segment of the right line. After selecting a cone, it becomes possible to determine its size and build its exact sweep since the cone is a unfolding surface. The sweep is constructed in the form of a flat ring with a cut sector and will be the desired flat workpiece to form a turn of the auger from it. Most accurately, the surface of the turn of the open helicoid can be made by stamping the workpiece of the resulting form. For small-scale production of the helical surface of an open helicoid, it is advisable to weld flat rings together and, during installation, stretch along the shaft while twisting around its axis. The accuracy of the obtained surface will depend on the accuracy of the approximation of the hyperboloid section of rotation with a truncated cone, which is the topic of this work.

Research on the Method of Reducing Dynamic Cutting Force in Aspheric Machining.

With the rapid development of photoelectric communication and other fields, the demand for high-precision aspheric mirrors has been increasing. Predicting dynamic cutting forces is vital in selecting machining parameters and also affects the surface quality of the machined surface. This study comprehensively considers the effects of different cutting parameters and workpiece shape parameters on dynamic cutting force. The actual width of cut, depth of cut, and shear angle are modelled while considering the effects of vibration. A dynamic cutting-force model considering the aforementioned factors is then established. Using experimental results, the model accurately predicts the average value of dynamic cutting force under different parameters and the range of fluctuation of dynamic cutting force, with a controlled relative error of about 15%. The influence of workpiece shape and workpiece radial size on dynamic cutting force is also considered. The experimental results show that the greater the surface slope, the more dramatic the dynamic cutting force fluctuations. This lays the foundation for subsequent writing on vibration suppression interpolation algorithms. The influence of the radius of the tool tip on dynamic cutting forces leads to the conclusion that to achieve the goal of reducing the fluctuation of cutting forces, diamond tools with different parameters should be selected for different feed rates. Finally, a new interpolation-point planning algorithm is used to optimize the position of interpolation points in the machining process. This proves the reliability and practicability of the optimization algorithm. The results of this study are of great significance to the processing of high-reflectivity spherical/aspheric surfaces.