Bore Cylindricity in Finish Cylinder Boring

2018 ◽  
Vol 140 (6) ◽  
Author(s):  
Lei Chen ◽  
Juhchin A. Yang ◽  
Albert J. Shih
Keyword(s):  
Thermal Expansion ◽  
Fem Analysis ◽  
Machining Process ◽  
Error Sources ◽  
Workpiece Temperature ◽  
Coordinate Measurement ◽  
Radial Error ◽  
Cylinder Bore ◽  
Error Motion ◽  
Cylindricity Error

Finish boring is a machining process to achieve the cylinder bore dimensional and geometrical accuracy. The bore cylindricity error sources, including the workpiece thermal expansion and deformation due to cutting and clamping forces, and spindle radial error motion, in finish boring were identified using combined experimental and finite element method (FEM) analysis. Experiments were conducted to measure the workpiece temperature, cutting and clamping forces, spindle error, and bore shape. FEM analysis of the workpiece temperature, thermal expansion, and deformation due to cutting and clamping forces was performed. The coordinate measurement machine (CMM) measurements of the bore after finish boring showed the 5.6 μm cylindricity and a broad spectrum from the second to tenth harmonics. The FEM revealed the effects of workpiece thermal expansion (1.7 μm cylindricity), deformation due to cutting force (0.8 μm cylindricity), and clamping force (1.9 μm cylindricity) on the finished bore and the dominance by the first to third harmonics using the three-jaw fixture. The spindle synchronous radial error motion (3.2 μm cylindricity) was dominated by the fourth and higher order harmonics and matched well with the high (above the fourth) harmonics in CMM measurements (2.9 μm cylindricity). The spindle error was the dominant error source for bore cylindricity in this finish boring study, contributing to about half of the total cylindricity error.

Evaluation Method to Determine Radial Error of Spindle Units on Simulation Turntable

2011 ◽  
Vol 460-461 ◽  
pp. 311-316
Author(s):  
Zhi Yong Qu ◽  
Jun Wei Han
Keyword(s):  
Small Angle ◽  
Evaluation Method ◽  
Simulation System ◽  
Transformation Matrix ◽  
Hardware In The Loop ◽  
Error Sources ◽  
Know How ◽  
Form Errors ◽  
Radial Error ◽  
Error Motion

Many errors including radial error influence the accuracy of simulation turntable, which is a crucial equipment in hardware-in-the-loop simulation system. The aim of this paper is to propose a new method of radial error motion separation of rotating spindle on a simulation turntable. Based on transformation matrix and small angle approximation, gesture transformation matrix with various error items is achieved. As a result of this analysis, form errors of master ball are corrected and the eccentricity from the rotation error of a spindle is separated. This radial error analysis is carried out when this measurement result is applied to a simulation turntable. Furthermore, this study also permits the user to know how to minimize some error sources of the spindle system.

Experimental Study and Finite Element Modeling of Workpiece Temperature in Finish Cylinder Boring

2017 ◽  
Vol 139 (11) ◽  
Author(s):  
Lei Chen ◽  
Bruce L. Tai ◽  
Juhchin A. Yang ◽  
Albert J. Shih
Keyword(s):  
Finite Element ◽  
Thermal Expansion ◽  
Temperature Distribution ◽  
Heat Carrier ◽  
Machined Surface ◽  
Workpiece Temperature ◽  
Advantages And Disadvantages ◽  
Carrier Model ◽  
Inverse Heat Transfer ◽  
Cylindricity Error

Thermal expansion of the workpiece during cylinder boring process is one of the sources causing the bore cylindricity error. To study thermal expansion induced bore distortion, detailed workpiece temperature distribution in cylinder boring is required. Four finite element models, namely, the advection model, surface heat model, heat carrier model, and ring heat model, were developed to predict the workpiece temperature in cylinder boring. Cylinder boring experiments were conducted utilizing the tool–foil and embedded thermocouple experimental approaches to measure the workpiece temperature, predict the temperature distribution using the inverse heat transfer method, and evaluate the capability of the four models in terms of accuracy and efficiency. Results showed an accurate global temperature prediction for all models and a good correlation with the embedded thermocouple experimental measurements. Good correlation was also obtained between the tool–foil thermocouple measurement of machined surface temperature and model predictions. Advantages and disadvantages as well as applicable scenarios of each model were discussed. For studying detailed cylinder boring workpiece temperature, it is suggested to use the ring heat model to estimate the moving heat flux and the heat carrier model for local workpiece temperature calculation.

Reduced Order Finite Element Modeling of Thermally Induced Bearing Loads in Machine Tool Spindles

1999 ◽  
Author(s):  
Alex O. Gibson ◽  
Jeffrey L. Stein
Keyword(s):  
Finite Element ◽  
Thermal Expansion ◽  
Machine Tool ◽  
Mechanical Load ◽  
Machining Process ◽  
Thermally Induced ◽  
Reduced Order ◽  
Wide Range ◽  
Bearing Load ◽  
Bearing Loads

Abstract Machine tool spindle bearings are subjected to a large range of axial and radial loads due to the machining process. Further the rotating spindle must be extremely stiff to minimize the cutting tool’s deflection. The high spindle stiffness is achieved by applying a mechanical load to the bearings, the preload. In fixed preload spindles the bearing loads tend to increase with increasing spindle speed due to thermal expansion and it is well established that these thermally induced loads can lead to premature bearing failure. A model of thermally induced bearing load in angular contact bearing spindles is developed that includes an axis-symmetric reduced order finite element model of the heat transfer and thermal expansion within the spindle’s housing and shaft and the bearing and shaft dynamics. Nodal reduction is used in the reduced order model to minimize the number of temperature states and the computational load. The reduced order model’s calculated temperature and bearing load values are shown to closely match experimentally measured values over a wide range of spindle speeds. The paper ends with a parameter variation study which predicts a dramatic decrease in the thermally induced bearing load when silicon nitride balls are substituted for steel balls.

scholarly journals Optical Setup for Error Compensation in a Laser Triangulation System

Sensors ◽  
2020 ◽  
Vol 20 (17) ◽  
pp. 4949
Author(s):  
Patrick Kienle ◽  
Lorena Batarilo ◽  
Markus Akgül ◽  
Michael H. Köhler ◽  
Kun Wang ◽  
...  
Keyword(s):  
Thermal Expansion ◽  
Measurement Errors ◽  
Beam Splitter ◽  
Reference Beam ◽  
Cost Effective ◽  
Laser Triangulation ◽  
Absolute Distance ◽  
Error Sources ◽  
Optical Setup ◽  
Achievable Accuracy

Absolute distance measurement is a field of research with a large variety of applications. Laser triangulation is a well-tested and developed technique using geometric relations to calculate the absolute distance to an object. The advantages of laser triangulation include its simple and cost-effective setup with yet a high achievable accuracy and resolution in short distances. A main problem of the technology is that even small changes of the optomechanical setup, e.g., due to thermal expansion, lead to significant measurement errors. Therefore, in this work, we introduce an optical setup containing only a beam splitter and a mirror, which splits the laser into a measurement beam and a reference beam. The reference beam can then be used to compensate for different error sources, such as laser beam dithering or shifts of the measurement setup due to the thermal expansion of the components. The effectiveness of this setup is proven by extensive simulations and measurements. The compensation setup improves the deviation in static measurements by up to 75%, whereas the measurement uncertainty at a distance of 1 m can be reduced to 85 μm. Consequently, this compensation setup can improve the accuracy of classical laser triangulation devices and make them more robust against changes in environmental conditions.

Study on the influence of machine tool spindle radial error motion resulted from bearing outer ring tilting assembly

2018 ◽  
Vol 233 (9) ◽  
pp. 3246-3258 ◽  
Author(s):  
Xiaohu Li ◽  
Ke Yan ◽  
Yifa Lv ◽  
Bei Yan ◽  
Lei Dong ◽  
...  
Keyword(s):  
Rotation Speed ◽  
Total Error ◽  
Experimental System ◽  
Outer Ring ◽  
Operation Condition ◽  
Thermal Displacement ◽  
Radial Error ◽  
Spindle Rotation ◽  
Motion Characteristics ◽  
Error Motion

To reveal the spindle radial error motion characteristics in condition of bearing outer ring tilting assembly, mathematical method on spindle radial error motion were analyzed. Then, in real operation condition the natural frequency of the test rig was investigated. Experimental system and methods were designed to test axial thermal displacement, radial error motion and modal characteristic of spindle in condition of bearing outer ring tilting assembly. Results show that axial thermal extension and radial vertical rising of spindle front-end occurs during thermal displacement test. With the same outer spacer nonparallelism, the synchronous error motion and total error motion generally increase with spindle rotation speed, and reach a peak at certain rotation speed.

scholarly journals Cylindricity Error Measuring and Evaluating for Engine Cylinder Bore in Manufacturing Procedure

2016 ◽  
Vol 2016 ◽  
pp. 1-7
Author(s):  
Qiang Chen ◽  
Xueheng Tao ◽  
Jinshi Lu ◽  
Xuejun Wang
Keyword(s):  
Least Square Method ◽  
Least Square ◽  
Zone Method ◽  
Method Error ◽  
Measuring Device ◽  
Engine Cylinder ◽  
Minimum Zone ◽  
Cylinder Method ◽  
Cylinder Bore ◽  
Cylindricity Error

On-line measuring device of cylindricity error is designed based on two-point method error separation technique (EST), which can separate spindle rotation error from measuring error. According to the principle of measuring device, the mathematical model of the minimum zone method for cylindricity error evaluating is established. Optimized parameters of objective function decrease to four from six by assuming thatcis equal to zero andhis equal to one. Initial values of optimized parameters are obtained from least square method and final values are acquired by the genetic algorithm. The ideal axis of cylinder is fitted in MATLAB. Compared to the error results of the least square method, the minimum circumscribed cylinder method, and the maximum inscribed cylinder method, the error result of the minimum zone method conforms to the theory of error evaluation. The results indicate that the method can meet the requirement of engine cylinder bore cylindricity error measuring and evaluating.

Analysis of error motions of axial locking-prevention hydrostatic spindle

2018 ◽  
Vol 233 (1) ◽  
pp. 3-17
Author(s):  
Penghai Zhang ◽  
Yaolong Chen
Keyword(s):  
Significant Influence ◽  
Harmonic Component ◽  
Necessary Condition ◽  
Third Harmonic ◽  
The Third ◽  
Fourth Harmonic ◽  
Radial Error ◽  
Tilt Error ◽  
Error Motion ◽  
Error Averaging

Hydrostatic spindles are widely used in precision optical grinder and lathe. Their high precision comes from the error averaging effect of oil film. The purpose of this paper is to give the quantitative analysis of the error averaging effect for a newly developed axial locking-prevention hydrostatic spindle. An approximate error motion model of the hydrostatic spindle is established to analyze the internal relationship between the geometric errors of the shaft and the error motions of the spindle including radial, tilt and axial error motions. The theoretical analysis shows that, the roundness errors of the two journals have a major impact on error motions while the coaxiality errors of two journals, the perpendicularity errors of front thrust plate and the coaxiality errors of the land of back thrust bearing, have no significant influences on error motions. The elliptical component of roundness errors of the two journals has significant influence on the axial error motion but no influence on the pure radial and tilt error motions, resulting into the fourth harmonic component of axial error motion. The trilobal component of roundness errors of the two journals has significant influence on the pure radial and tilt error motions but no influence on the axial error motion, resulting in the third harmonic component of pure radial and tilt error motions. The changes of recess pressures are not necessary condition for the error motions. Additionally, the experiment analysis shows that, the third harmonic component is the main part of the measured radial error motion and the third, fourth harmonic components are the main parts of the measured face error motion, which can be reasonably explained by the theory. The model proposed in this paper can be used to guide the precision design and optimization of hydrostatic spindle.

A Study on Cylinder Bore Deformation of a Diesel Engine With Dry Liner Structure

2001 ◽  
Author(s):  
Shigeto Yamamoto ◽  
Hiroshi Sakita ◽  
Masaaki Takiguchi ◽  
Shinichi Sasaki
Keyword(s):  
Thermal Expansion ◽  
Diesel Engine ◽  
Room Temperature ◽  
Engine Speed ◽  
Cylinder Liner ◽  
Cylinder Block ◽  
Cylinder Pressure ◽  
Engine Operation ◽  
Actual Operation ◽  
Cylinder Bore

Abstract The deformation of the cylinder liner of a diesel engine in actual operation have been measured by the means of a rotary piston, and the deformation has been compared with those measured statically at room temperature. As a result, it is found that the deformation of the liner in engine operation is hardly affected by the deformation at room temperature, but it follows the deformation of the cylinder block where the liner is inserted. It is also found as follows: The deformation of the liner upper portion varies according to the head bolts and the engine load, while the effect of the cylinder pressure is insignificant. The deformation at the middle of the liner changes mainly by the thermal expansion in the thrust direction, while the deformation at the lower portion is not affected by the engine speed or the load.

Tool-Workpiece Temperature for Continuous and Interrupted Cutting of ASSAB 760 Steel with Dry Machining Process

2012 ◽  
Vol 476-478 ◽  
pp. 392-396
Author(s):  
M. Azuddin
Keyword(s):  
Feed Rate ◽  
Thermal Imaging ◽  
Temperature Increase ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Workpiece Temperature ◽  
Speed Increase ◽  
Interrupted Cutting ◽  
Imaging Camera

Temperature generated on the tool-workpiece has significant effect on the cutting performance. This paper present the tool-workpiece temperature result recorded by thermal imaging camera with various cutting parameter applied. The machining was done on ASSAB 720 steel workpiece for continuous and interrupted cutting. Generally, as the cutting speed, feed rate and depth of cut increases, the tool-workpiece temperature for both continuous and interrupted cutting will increase. Specifically, cutting speed increase from 250m/min to 350 m/min, tool-workpiece temperature increase about 25% at each increment level. The tool-workpiece temperature increase about 16% when the feed rate increases from 0.1 mm/rev to 0.2mm/rev. While, 27% increment was recorded when feed rate increase to 0.4 mm/rev. With the increase of depth of cut, the tool-workpiece temperature recorded an increment between 50oC to 65oC for both continuous and interrupted cutting.

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