To automatically measure the surface profile of a cylindrical workpiece, a high-precision multi-beam optical method is proposed in this paper. First, some successive images for the cylindrical workpiece's surface are acquired by a multi-beam angle sensor under different light directions. Then, the light directions are estimated based on the feature regions in the images to calculate surface normal vectors. Finally, according to the relationship of the surface normal vector and the vertical section of the workpiece's surface, a depth map is reconstructed to achieve the curvature surface, which can be employed to measure the curvature radius of the cylindrical workpiece's surface. Experimental results indicate that the proposed measurement method can achieve good measurement precision with a mean error of the curvature radius of a workpiece's surface of 0.89% at a reasonable speed of 10.226 s, which is superior to some existing methods.
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http://dx.doi.org/10.3390/mi14081555 | DOI Listing |
Sci Rep
February 2024
School of Mechatronic Engineering, Xi'an Technological University, No.2 Xuefu Middle Street, Weiyang District, Xi'an, 710021, China.
Due to its challenging manufacturing and intricate morphology, the aluminum alloy transmission intermediate shell used in vehicle transmission has been the focus of many academic studies. In this study, the three-dimensional cutting model is condensed to a two-dimensional cutting model and utilized to simulate the finishing process of an aluminum alloy workpiece using the finite element modeling program DEFORM-3D. Through orthogonal testing and range analysis, the impact of integral end mill side edge parameters on cutting performance was investigated.
View Article and Find Full Text PDFMicromachines (Basel)
August 2023
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou 510006, China.
To automatically measure the surface profile of a cylindrical workpiece, a high-precision multi-beam optical method is proposed in this paper. First, some successive images for the cylindrical workpiece's surface are acquired by a multi-beam angle sensor under different light directions. Then, the light directions are estimated based on the feature regions in the images to calculate surface normal vectors.
View Article and Find Full Text PDFMaterials (Basel)
June 2023
School of Mechanical and Electrical Engineering, Soochow University, Suzhou 215137, China.
Titanium alloy is a crucial structural material in the modern aerospace field due to its strong corrosion resistance and strength, low density, and reduced sensitivity to vibration load and impact load, as well as its ability to resist expansion in the case of cracks. However, during high-speed cutting of titanium alloy, it is prone to periodic saw-tooth chip formation, which can cause high-frequency fluctuations in the cutting force, aggravate the vibration of the machine tool system, and ultimately reduce the tool's service life and the workpiece's surface quality. In this study, we investigated the influence of the material constitutive law in modeling the Ti-6AL-4V saw-tooth chip formation and proposed a joint material constitutive law JC-TANH which was developed based on the Johnson-Cook constitutive law and the TANH constitutive law.
View Article and Find Full Text PDFSensors (Basel)
April 2023
Department of Mechanical Engineering, National Taiwan University of Science and Technology, Taipei 106, Taiwan.
The use of robots for machining operations has become very popular in the last few decades. However, the challenge of the robotic-based machining process, such as surface finishing on curved surfaces, still persists. Prior studies (non-contact- and contact-based) have their own limitations, such as fixture error and surface friction.
View Article and Find Full Text PDFMicromachines (Basel)
March 2023
Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China.
The plastic deformation behavior and microstructural changes in workpieces during ultra-precision machining have piqued the interest of many researchers. In this study, a molecular dynamics simulation of nano-cutting iron-carbon alloy (α-Fe) is established to investigate the effects of the fluid medium and cutting angle on workpiece temperature, friction coefficient, workpiece surface morphology, and dislocation evolution by constructing a molecular model of C12H26 as a fluid medium in the liquid phase using an innovative combined atomic approach. It is demonstrated that the presence of the fluid phase reduces the machining temperature and the friction coefficient.
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