Modeling of Workpiece Location Error Due to Fixture Geometric Error and Fixture-Workpiece Compliance

2005 ◽  
Vol 127 (1) ◽  
pp. 75-83 ◽  
Author(s):  
Anand Raghu ◽  
Shreyes N. Melkote
Keyword(s):  
Cutting Tool ◽  
Geometric Error ◽  
Location Error ◽  
Error Sources ◽  
Linear Elastic ◽  
Contact Points ◽  
Influence Coefficients ◽  
Machining System ◽  
Bulk Elasticity

Several fixture-related error sources contribute to workpiece location error in a machining system. Inaccurate part placement in the fixture relative to the cutting tool, for example, can negatively affect the quality of the part. In this paper, the following major sources of error are considered: fixture geometric error and elastic deformation of the fixture and workpiece due to fixturing forces. The workpiece location error is predicted by modeling the process of part loading (given fixture geometric variations) and clamping (given deformations at the contact points) in a machining fixture. Linear elastic models for the fixture elements, contact mechanics models for the contact regions, and flexibility influence coefficients to capture the bulk elasticity of the workpiece have been used to model the compliance of the entire fixture-workpiece system. The deformations at the contact points are obtained by solving a constrained optimization model. The effect of geometric errors and compliance on workpiece location error is examined using part response points as a measure of quality. Experimental validation is also provided for several fixture-workpiece variable levels using a 3-2-1 machining fixture.

Prediction of Workpiece Location Error Due to Fixture Geometric Errors and Fixture-Workpiece Compliance

Manufacturing ◽  
2003 ◽  
Author(s):  
Anand Raghu ◽  
Shreyes N. Melkote
Keyword(s):  
Geometric Error ◽  
Influence Coefficient ◽  
Geometric Errors ◽  
Location Error ◽  
Error Sources ◽  
Linear Elastic ◽  
Part Quality ◽  
Contact Points ◽  
Influence Coefficient Method ◽  
Coefficient Method

Workpiece location relative to the cutting tool is affected by the accuracy of part placement in the fixture. A number of error sources are known to contribute to the resulting workpiece location error, which can lead to poor part quality. The major sources include fixture geometric error and elastic deformation of the fixture and workpiece due to fixturing forces. In this paper, workpiece location error is predicted by modeling the process of part loading (given fixture geometric variations) and clamping (given deformations at the contact points) in a machining fixture. Linear elastic models for the fixture elements, contact mechanics models at the region of contact, and the flexibility influence coefficient method for the bulk elasticity of the workpiece have been used to model the compliance of the entire fixture-workpiece system. The deformations at the contact points are obtained by solving a constrained optimization model. The effect of geometric errors and compliance on workpiece location error is examined using part response points as a measure of quality, through examples involving a 3-2-1 machining fixture.

Dynamic Behavior of Long Turned Workpieces

2014 ◽  
Vol 657 ◽  
pp. 78-82 ◽  
Author(s):  
Neculai Eugen Seghedin ◽  
Mihăiţă Horodincă ◽  
Dragos Chitariu ◽  
Radu Drosescu
Keyword(s):  
Machine Tool ◽  
Dynamic Behavior ◽  
Cutting Tool ◽  
Machining Process ◽  
Technological System ◽  
System Stability ◽  
Machining System ◽  
Dynamic Quality ◽  
Tool Cutting

One of the most important parameters used in the evaluation of machining technological systems is the dynamic quality, represented by the system stability and the specific feature of the reaction to the external factors, during the machining process. The dynamic quality of the machining system is given by the dynamic quality of the machine tool, cutting tool, cutting tool holding device, workpiece fixture. The dynamic behavior of the machining system is given by the behavior of the elastic subsystem of the workpiece and tool. In the case that the deformation of the machine tool is negligible in relation with the two subcomponents of the technological system, mentioned, these can be studied separately. It is important to determine which is the weakest link of the technological system or to determine which is the component that can lead to the loss of the stability of the entire system. In the paper it is studied the dynamic behavior of the turned long, flexible workpieces. The workpieces are clamped in the lathes chuck and in the tailstock. The natural vibrational frequencies are determined according to a series of parameters as the diameter of the workpieces, axial forces applied by the tailstock.

Dynamics of the processes in metal machining

1998 ◽  
Vol 2 ◽  
pp. 115-122
Author(s):  
Donatas Švitra ◽  
Jolanta Janutėnienė
Keyword(s):  
High Frequency ◽  
Machine Tools ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Low Frequency ◽  
Metal Cutting Machine ◽  
Cutting Machine ◽  
Metal Machining

In the practice of processing of metals by cutting it is necessary to overcome the vibration of the cutting tool, the processed detail and units of the machine tool. These vibrations in many cases are an obstacle to increase the productivity and quality of treatment of details on metal-cutting machine tools. Vibration at cutting of metals is a very diverse phenomenon due to both it’s nature and the form of oscillatory motion. The most general classification of vibrations at cutting is a division them into forced vibration and autovibrations. The most difficult to remove and poorly investigated are the autovibrations, i.e. vibrations arising at the absence of external periodic forces. The autovibrations, stipulated by the process of cutting on metalcutting machine are of two types: the low-frequency autovibrations and high-frequency autovibrations. When the low-frequency autovibration there appear, the cutting process ought to be terminated and the cause of the vibrations eliminated. Otherwise, there is a danger of a break of both machine and tool. In the case of high-frequency vibration the machine operates apparently quiently, but the processed surface feature small-sized roughness. The frequency of autovibrations can reach 5000 Hz and more.

Analysis of structures of flat planting machines

2021 ◽  
Vol 13 (1) ◽  
pp. 140-148
Author(s):  
Andrіі Slabkyі ◽  
◽  
Olexandr Manzhilevskyy ◽  
Olexandr Polishchuk ◽  
◽  
...  
Keyword(s):  
Cutting Tool ◽  
Relative Movement ◽  
Statistical Parameters ◽  
Abrasive Finishing ◽  
Wide Range ◽  
Uneven Wear ◽  
Lapping Machine ◽  
Numerical Program ◽  
Hydraulic Pulse

One of the methods of material processing is considered, which allows to obtain high geometric accuracy and low surface roughness of parts, namely their abrasive finishing. The high quality of machining of parts in this way is due to the use of coordinated relative movement of the workpiece and the cutting tool. According to the kinematic features, most lapping machines can be divided into two groups: machines with oscillating working motion and machines with rotating lapping motion. The machines of the first group are more common due to the simplicity of their design and versatility. However, the possibility of their use is limited by the size range of the workpieces and uneven wear of the cutting tool and, as a consequence, the uneven surface treatment of the part. The machines of the second group are considered the most versatile, as they allow processing a wide range of parts, varying in shape and size, but they are also not without such a disadvantage as uneven wear of the cutting tool with all the corresponding consequences. Improving the efficiency of abrasive finishing by complicating the trajectory of the relative movement of the tool and the part, ie the formation of a unique mutual working movement of the lapping and the movement of the workpiece, is one of the most common areas. The main disadvantage of equipment that provides processing of parts on this principle is, in most cases, limited regulation of the operating parameters of the cutting process, so this area remains promising and has broad prospects for development. The constructive scheme of the hydraulic-pulse flat-lapping machine offered in work thanks to a combination of advantages of the hydraulic-pulse drive with use of numerical program control will allow to provide unique mutual multi-movement of preparation and the lapping tool with a possibility of adjustment of its parameters in the course of processing. Purposeful choice of the shape and density of the trajectory of the working movement of the tool will form a micro relief of the treated surface with the necessary statistical parameters and low roughness.

ENSURING QUALITATIVE-ACCURACY CHARACTERISTICS DURING RESTORING OF VEHICLE PARTS

2021 ◽  
Vol 3 (144) ◽  
pp. 116-121
Author(s):  
Nikita A. Pen’kov ◽  
◽  
Oleg A. Sidorkin ◽  
Sergey Yu. Zhachkin ◽  
Anatoliy I. Zavrazhnov ◽  
...  
Keyword(s):  
Wear Resistance ◽  
Current Density ◽  
Hydraulic Drive ◽  
Research Purpose ◽  
Working Fluid ◽  
Agricultural Machinery ◽  
Servo Valve ◽  
Contact Points ◽  
Drive Systems

One of the most common reasons for the failure of hydraulic drive systems for agricultural machinery is the working fluid leak in the contact points of the rubbing surfaces of hydraulic blocks. The application of composite coatings based on chromium on the contacting surfaces allows you to restore the defect in the shape of the part caused by wear, as well as reduce the friction coefficient at the contact points, which positively affects the wear resistance of the part. (Research purpose) The research purpose is in developing technologies for restoring parts of agricultural machinery with predetermined operational properties. (Materials and methods) A servo valve, widely used in various hydraulic drive systems, was used as an experimental sample. Its working surface was restored with a composite coating applied by electroplating to increase the wear resistance of the servo valve. (Results and discussion) Authors conducted a series of direct measurements under the same conditions. The article presents the de-pendence of the microhardness on the parameters of the electrolysis mode and the thickness of the applied coating using the method of least squares. The nature of changes in microhardness and residual stresses was evaluated to determine the quality of the coatings. The article presents the dependences of these indicators on various control parameters (current density, temperature, tool pressure). The equations of the regression of the main qualitative and accuracy characteristics of the parts were deter-mined using the apparatus of the theory of experimental planning. (Conclusions) The article presents the method for predicting coatings of a given quality, taking into ac-count the influence of the current density and the temperature of the electrolyte during electrolysis on the nature of the precipitation obtained. The influence of the tool pressure on the depth of deformation of the formed layers was estimated. This approach allows us to evaluate the nature of the stress distribution in the formed coating and the quality of the restored parts.

THRUST FORCE PREDICTION MODEL FOR DRILLING UNIDIRECTIONAL CARBON PLASTICS WITH WEAR OF THE CUTTING TOOL

2021 ◽  
Vol 2 ◽  
pp. 100-108
Author(s):  
V.I. GOLOVIN ◽  
S.YU. RADCHENKO
Keyword(s):  
Carbon Fiber ◽  
Tool Wear ◽  
Prediction Model ◽  
Cutting Tool ◽  
Thrust Force ◽  
Contact Conditions ◽  
Force Prediction ◽  
Geometric Characteristics ◽  
Drill Tool

One of the most important tasks in the production of carbon fiber products is to ensure the specified accuracy and quality of the drilled holes. A model for predicting the thrust force, taking into account the degree of tool wear, is proposed. First, the geometric characteristics of the wear of the spiral drill tool are analyzed. Further, the contact conditions between the drill and the carbon fiber are determined in accordance with the geometric characteristics of the tool wear. Based on the mechanics of the contact interaction of surfaces, the thrust forces of the main cutting edges and the chisel edge are modeled, taking into account the degree of tool wear. The results obtained are integrated into the thrust force prediction model. An example of an experimental study of the drilling carbon fiber is given. The results obtained show a fairly accurate prediction of the cutting force, taking into account the wear of the cutting tool.

scholarly journals Assessing the quality of ionospheric models through GNSS positioning error: methodology and results

GPS Solutions ◽  
2019 ◽  
Vol 24 (1) ◽  
Author(s):  
Adrià Rovira-Garcia ◽  
Deimos Ibáñez-Segura ◽  
Raul Orús-Perez ◽  
José Miguel Juan ◽  
Jaume Sanz ◽  
...  
Keyword(s):  
Satellite System ◽  
Ionospheric Delay ◽  
Single Frequency ◽  
Positioning Error ◽  
Dual Frequency ◽  
Error Sources ◽  
Ionospheric Models ◽  
Evaluation Metric ◽  
Global Navigation Satellite

Abstract Single-frequency users of the global navigation satellite system (GNSS) must correct for the ionospheric delay. These corrections are available from global ionospheric models (GIMs). Therefore, the accuracy of the GIM is important because the unmodeled or incorrectly part of ionospheric delay contributes to the positioning error of GNSS-based positioning. However, the positioning error of receivers located at known coordinates can be used to infer the accuracy of GIMs in a simple manner. This is why assessment of GIMs by means of the position domain is often used as an alternative to assessments in the ionospheric delay domain. The latter method requires accurate reference ionospheric values obtained from a network solution and complex geodetic modeling. However, evaluations using the positioning error method present several difficulties, as evidenced in recent works, that can lead to inconsistent results compared to the tests using the ionospheric delay domain. We analyze the reasons why such inconsistencies occur, applying both methodologies. We have computed the position of 34 permanent stations for the entire year of 2014 within the last Solar Maximum. The positioning tests have been done using code pseudoranges and carrier-phase leveled (CCL) measurements. We identify the error sources that make it difficult to distinguish the part of the positioning error that is attributable to the ionospheric correction: the measurement noise, pseudorange multipath, evaluation metric, and outliers. Once these error sources are considered, we obtain equivalent results to those found in the ionospheric delay domain assessments. Accurate GIMs can provide single-frequency navigation positioning at the decimeter level using CCL measurements and better positions than those obtained using the dual-frequency ionospheric-free combination of pseudoranges. Finally, some recommendations are provided for further studies of ionospheric models using the position domain method.

scholarly journals Improving the Performance of Steel Machining Processes through Cutting by Vibration Control

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5712
Author(s):  
Mihaela Oleksik ◽  
Dan Dobrotă ◽  
Mădălin Tomescu ◽  
Valentin Petrescu
Keyword(s):  
Fourier Transformation ◽  
Vibration Analysis ◽  
Cutting Tool ◽  
Cutting Process ◽  
Manufacturing Processes ◽  
Machining Processes ◽  
Short Time ◽  
Short Time Fourier Transformation ◽  
Dynamic Phenomena

Machining processes through cutting are accompanied by dynamic phenomena that influence the quality of the processed surfaces. Thus, this research aimed to design, make, and use a tool with optimal functional geometry, which allowed a reduction of the dynamic phenomena that occur in the cutting process. In order to carry out the research, the process of cutting by front turning with transversal advance was taken into account. Additionally, semi-finished products with a diameter of Ø = 150 mm made of C45 steel were chosen for processing (1.0503). The manufacturing processes were performed with the help of two tools: a cutting tool, the classic construction version, and another that was the improved construction version. In the first stage of the research, an analysis was made of the vibrations that appear in the cutting process when using the two types of tools. Vibration analysis considered the following: use of the Fast Fourier Transform (FFT) method, application of the Short-Time Fourier-Transformation (STFT) method, and observation of the acceleration of vibrations recorded during processing. After the vibration analysis, the roughness of the surfaces was measured and the parameter Ra was taken into account, but a series of diagrams were also drawn regarding the curved profiles, filtered profiles, and Abbott–Firestone curve. The research showed that use of the tool that is the improved constructive variant allows accentuated reduction of vibrations correlated with an improvement of the quality of the processed surfaces.

Microtexture Generation Using Controlled Chatter Machining in Ultraprecision Diamond Turning

2015 ◽  
Vol 3 (2) ◽  
Author(s):  
Syed Adnan Ahmed ◽  
Jeong Hoon Ko ◽  
Sathyan Subbiah ◽  
Swee Hock Yeo
Keyword(s):  
Cutting Tool ◽  
Cutting Speed ◽  
Diamond Turning ◽  
Diamond Cutting ◽  
Machined Surface ◽  
Excited Vibration ◽  
Mass And Heat Transfer ◽  
Tool Shank ◽  
Diamond Cutting Tool

This paper describes a new method of microtexture generation in precision machining through self-excited vibrations of a diamond cutting tool. Conventionally, a cutting tool vibration or chatter is detrimental to the quality of the machined surface. In this study, an attempt is made to use the cutting tool's self-excited vibration during a cutting beneficially to generate microtextures. This approach is named as “controlled chatter machining (CCM).” Modal analysis is first performed to study the dynamic behavior of the cutting tool. Turning processes are then conducted by varying the tool holder length as a means to control vibration. The experimental results indicate that the self-excited diamond cutting tool can generate microtextures of various shapes, which depend on the cutting tool shank, cutting speed, feed, and cutting depth. The potential application of this proposed technique is to create microtextures in microchannels and microcavities to be used in mass and heat transfer applications.

A NEW METHOD OF LENS CENTERING IN THE OPTICAL SYSTEM BY USING SPECIAL MOUNT

2021 ◽  
pp. 137-144
Author(s):  
Bao Bui Dinh
Keyword(s):  
Optical System ◽  
Optical Axis ◽  
Assembly Process ◽  
Optical Surface ◽  
Lens System ◽  
High Quality ◽  
Manufacturing Equipment ◽  
Influence Coefficients ◽  
Process Solutions

Decentration in lens systems (for example objectives) significantly degrades the quality of image, such as the coma. In order to reduce lens decentration, the lenses are centered while manufacturing, while gluing, while attachment in the mounts. Significant decrease in the lenses decentering in the mounts is achieved by using a special manufacturing equipment, which allow combining the optical axis of the lens with the base axis of the mount in assembly process. Solutions for coma's alignment by shifting, tilting and rotation their components are also provided in the construction of high-quality objectives (microscopes [1-7], photolithographic, aerophotographic). For optimization of methods for such adjustment the influence coefficients of decentering of each optical surface of the lens system on the value and sign of coma must be calculated and taken into account. In this paper, we propose a special mounting which combined with the Opticentric of Trioptics device to center the lenses. The results show that the decentering is significantly reduced (0.9µm) compared to (44.2µm) with using a reference mount.

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