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Dynamics analysis of a slender ball-screw feed system considering the changes of the worktable position SCIE
期刊论文 | 2019 , 233 (8) , 2685-2695 | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
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Abstract :

For a slender ball-screw feed system, the position of the screw-nut joints will change greatly when the moving worktable moves along its whole stroke. Therefore, the compression/tension and torsion stiffness of the screw-shaft on both sides of the screw-nut joints will change. Thus, the system transmission stiffness will also vary and affect its dynamics. In this article, considering the changes of the worktable position and using hybrid element method, a dynamic model was established for the slender ball-screw feed system, and a calculation method of the system stiffness and mass matrix was provided. The experiments on the slender ball-screw feed system with different positions were also performed to verify the proposed dynamic model. Finally, the influences of length, screw-tension force, pitch, nominal diameter of screw and rated dynamic load of screw-nut joints on the slender ball-screw feed system's natural frequency along its whole stroke were studied. The results showed that the slender ball-screw feed system possesses obvious position-dependent variable dynamics along its whole stroke; the ratio of length to diameter of the screw (L-f/d(0)) would be better designed smaller than 50 in order to obtain the relative uniformity of the system dynamics when manufacturing large machine tools.

Keyword :

dynamics analysis modeling method stiffness slender ball-screw feed system Machine tool

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GB/T 7714 Zhang, Huijie , Liu, Hui , Du, Chao et al. Dynamics analysis of a slender ball-screw feed system considering the changes of the worktable position [J]. | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE , 2019 , 233 (8) : 2685-2695 .
MLA Zhang, Huijie et al. "Dynamics analysis of a slender ball-screw feed system considering the changes of the worktable position" . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE 233 . 8 (2019) : 2685-2695 .
APA Zhang, Huijie , Liu, Hui , Du, Chao , Lv, Dun , Zhang, Jun , Zhao, Wanhua . Dynamics analysis of a slender ball-screw feed system considering the changes of the worktable position . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE , 2019 , 233 (8) , 2685-2695 .
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A novel precision evaluation and analysis method for the direct driven high-speed feed system EI SCIE
期刊论文 | 2019 , 121 , 689-710 | Mechanical Systems and Signal Processing
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Abstract :

The direct driven feed system incorporates the merits of simple structure, high velocity and high acceleration, which has a bright future in the high-speed machine tools. However, because of the absence of the intermediate transmission components, there are different kinds of the disturbances which directly act on the mechanical system, leading to multiform motion errors. The complex motion errors in different motion processes will affect the final dynamic performance of the feed system with different forms and degrees, and finally affect the machining precision of the workpiece. It is of great significance to find a comprehensive and systematic precision evaluation method for the analysis and improvement of the dynamic precision of the feed system. In this paper, based on the motion characteristics and error sources, a novel precision evaluation and analysis method and indexes are proposed for the direct driven feed system. The electromechanical integrated model is established and then the dynamic precision in different motion processes with multi-source inputs are analytical presented. What is more, the experimental verification is carried out with different velocities. The results demonstrate that the proposed method can systematically evaluate the dynamic performance of direct drive high-speed feed system. Finally, the sensitive parameters of the precision evaluation indexes are discussed using the sensitivity analysis method (SAM), and the corresponding improvement measures are put forward. © 2018 Elsevier Ltd

Keyword :

Analytical presentation Dynamic precision Electromechanical integrated Experimental verification Feed systems High-speed machine tools Parameter sensitivity analysis Transmission components

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GB/T 7714 Yang, Xiaojun , Liu, Hui , Yang, Qingyu et al. A novel precision evaluation and analysis method for the direct driven high-speed feed system [J]. | Mechanical Systems and Signal Processing , 2019 , 121 : 689-710 .
MLA Yang, Xiaojun et al. "A novel precision evaluation and analysis method for the direct driven high-speed feed system" . | Mechanical Systems and Signal Processing 121 (2019) : 689-710 .
APA Yang, Xiaojun , Liu, Hui , Yang, Qingyu , Zhao, Wanhua . A novel precision evaluation and analysis method for the direct driven high-speed feed system . | Mechanical Systems and Signal Processing , 2019 , 121 , 689-710 .
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Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter EI Scopus SCIE
期刊论文 | 2019 , 233 (1) , 226-242 | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
WoS CC Cited Count: 2 SCOPUS Cited Count: 2
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Abstract :

An enhanced time-domain simulation method of cutter/workpiece dynamic engagement during milling process is proposed in this article, which comprehensively considers the effect of multi-order modal characteristics of cutter system and cutter runout including offset and inclination. Based on the cutter dynamic displacement response, this article further presents the machined surface reconstruction algorithm and evaluation method for the form error. This research systematically studies and compares the calculation accuracy between the proposed method and other previous three kinds of methods. The effectiveness of the proposed method has been verified by a series of milling experiments successfully. By comparing with the other three methods, the proposed method shows a high calculation performance, especially under the milling condition with a large axial depth of cut and low damping or stiffness of cutter system. Besides, the results indicate that the form error has a strong dependence characteristic on the milling parameters, particularly on spindle speed. Additionally, cutter runout would easily cause over cut phenomenon on the machined surface and seriously deteriorate the surface roughness. © 2017, IMechE 2017.

Keyword :

Axial depth of cut Calculation accuracy Cutter runout Form errors Machined surface topography Milling process Modal characteristics Time-domain simulations

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GB/T 7714 Zhang, Xing , Zhang, Wei , Zhang, Jun et al. Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter [J]. | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture , 2019 , 233 (1) : 226-242 .
MLA Zhang, Xing et al. "Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter" . | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233 . 1 (2019) : 226-242 .
APA Zhang, Xing , Zhang, Wei , Zhang, Jun , Pang, Bo , Zhao, Wanhua . Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter . | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture , 2019 , 233 (1) , 226-242 .
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An investigation of spectral characteristic of displacement fluctuation and its effect on surface quality in precision machining EI SCIE Scopus
期刊论文 | 2018 , 98 (5-8) , 1605-1615 | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
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Abstract :

In precision machining, the machining conditions play an important role in part surface quality, because the characteristic of the exciting source in machine tools has a close relationship with the machining conditions. Therefore, this paper investigates the spectral characteristic of displacement fluctuation and its effect on the part surface quality for ball screw feed systems. The spectral characteristic is deduced by an equivalent disturbance model that considers the error sources of permanent magnet synchronous motor drives. In the spectrum of displacement fluctuation, the amplitudes of some spectral components increase with the load force; the corresponding frequencies are even multiples of the fundamental frequency of phase current and of the fundamental frequency of phase current plus or minus the rotor frequency. The resonance due to the variation of spectrum seriously deteriorates the part surface quality, leading to visible and characteristic patterns on the surface of machined parts. In the paper, two solutions to improve the surface quality are proposed and validated, i.e., the control method based on an adaptive filter and the method with constraint of feed rate.

Keyword :

Spectral characteristic Part surface quality Ball screw feed systems Precision machining Displacement fluctuation

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GB/T 7714 Liang, Tao , Zhang, Xing , Zhao, Wanhua . An investigation of spectral characteristic of displacement fluctuation and its effect on surface quality in precision machining [J]. | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2018 , 98 (5-8) : 1605-1615 .
MLA Liang, Tao et al. "An investigation of spectral characteristic of displacement fluctuation and its effect on surface quality in precision machining" . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 98 . 5-8 (2018) : 1605-1615 .
APA Liang, Tao , Zhang, Xing , Zhao, Wanhua . An investigation of spectral characteristic of displacement fluctuation and its effect on surface quality in precision machining . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2018 , 98 (5-8) , 1605-1615 .
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Electromechanical integrated modeling and analysis for the direct-driven feed system in machine tools EI SCIE Scopus
期刊论文 | 2018 , 98 (5-8) , 1591-1604 | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
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Abstract :

The permanent magnet linear synchronous motor (PMLSM) feed system realizes the direct drive. All the intermediate mechanical transmission parts are canceled and then the motor mover is directly connected with the driven components. The interaction between servo system and mechanical system becomes more close and complex, affecting the dynamic performance of the direct-driven feed system. In this paper, the dynamic characteristics of the drive circuit, PMLSM, control loops, and mechanical system are analyzed, and then an electromechanical integrated modeling method for the direct-driven feed system is proposed. Firstly, the dynamic precision of the feed system and electromechanical analytical model is studied. Then the nonlinearities of the drive circuit and PMLSM are researched. The analytical expression of the motor thrust is derived. What is more, the mechanical dynamic model is set up using the Lagrange equation and the main forms of the vibrations are discussed. Finally, the electromechanical integrated model is established and the experiments are carried out to verify the theoretical results. The results show that the proposed integrated modeling method can accurately represent the dynamic precision of the direct-driven feed system, which can provide the theoretical foundation for analyzing the electromechanical couplings and compensation methods.

Keyword :

Servo system Direct-driven feed system Electromechanical integrated model Dynamic precision Mechanical system

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GB/T 7714 Yang, Xiaojun , Lu, Dun , Liu, Hui et al. Electromechanical integrated modeling and analysis for the direct-driven feed system in machine tools [J]. | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2018 , 98 (5-8) : 1591-1604 .
MLA Yang, Xiaojun et al. "Electromechanical integrated modeling and analysis for the direct-driven feed system in machine tools" . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 98 . 5-8 (2018) : 1591-1604 .
APA Yang, Xiaojun , Lu, Dun , Liu, Hui , Zhao, Wanhua . Electromechanical integrated modeling and analysis for the direct-driven feed system in machine tools . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2018 , 98 (5-8) , 1591-1604 .
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Interfacial effects on the dynamic stresses in high speed cutting of heterogeneous materials EI
会议论文 | 2018 , 77 , 151-154 | 8th CIRP Conference on High Performance Cutting, HPC 2018
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Abstract :

The microstructure of materials has an important effect on the chip formation and fracture process during metal cutting. Its heterogeneity makes the dynamic mechanical response of materials complicated, which would become more notable with the increase of cutting speed. In this paper, a spring-network discrete element model was established to characterize the heterogeneous material for cutting simulation. The dynamic stress propagation was investigated during the cutting tool impacting on the workpiece at high speeds. Voronoi tessellation method was utilized to create polycrystalline structures in the model and the stress distribution was discussed. Compared with the results by the homogeneous model, the distribution of dynamic stress in polycrystalline model is obviously discontinuous. Furthermore, the normal stress and shear stress propagates in the workpiece as longitudinal and transverse stress waves, which are reflected and transmitted at interfaces. The fluctuation of stress triaxiality is more obvious and changes significantly with the increase of cutting speed, which provides an idea for explaining the fracture mode transition of material in high speed cutting process. © 2018 The Authors. Published by Elsevier Ltd.

Keyword :

Discrete element modeling Dynamic mechanical response Fracture mode transitions Heterogeneous materials High speed cutting Polycrystalline models Polycrystalline structure Stress wave propagation

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GB/T 7714 He, Yong , Zhang, Jun , Jiang, Yifei et al. Interfacial effects on the dynamic stresses in high speed cutting of heterogeneous materials [C] . 2018 : 151-154 .
MLA He, Yong et al. "Interfacial effects on the dynamic stresses in high speed cutting of heterogeneous materials" . (2018) : 151-154 .
APA He, Yong , Zhang, Jun , Jiang, Yifei , Liu, Zhechao , Qi, Yutong , Zhao, Wanhua . Interfacial effects on the dynamic stresses in high speed cutting of heterogeneous materials . (2018) : 151-154 .
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Effect of morphological evolution of serrated chips on surface formation during high speed cutting Ti6Al4V EI
会议论文 | 2018 , 77 , 147-150 | 8th CIRP Conference on High Performance Cutting, HPC 2018
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Abstract :

Ti6Al4V alloys are widely used in aerospace industry due to its excellent mechanical properties, however, serrated chips are easily formed in high speed cutting and have great influence on the surface formation process. In this study, high speed cutting experiments and simulations ranging from 125-750m/min are conducted to explore the characteristics of serrated chips and surface quality. Accordingly, the evolution of serrated chips characteristics and its effect on cutting force and machined surface are discussed. The results show that the inhomogeneous plastic deformation of serrated chips directly causes the cutting forces fluctuation and then leads to the microwaves of machined surface. Furthermore, the surface toughness reaches the highest around 250 m/min and then decrease with the increase of cutting speed, meanwhile, as for the surface defect dimples, their shapes get equiaxed and sizes become small, which shows that the surface quality is improved by increasing the cutting speed. Therefore, surface quality could be controlled by optimizing cutting parameters with better understanding of the influence of chips evolution on machined surface quality. © 2018 The Authors. Published by Elsevier Ltd.

Keyword :

Cutting forces Cutting parameters High speed cutting Inhomogeneous plastic deformation Machined surface quality Morphological evolution Serrated chip Surface formation

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GB/T 7714 Xu, Xiang , Zhang, Jun , Liu, Hongguang et al. Effect of morphological evolution of serrated chips on surface formation during high speed cutting Ti6Al4V [C] . 2018 : 147-150 .
MLA Xu, Xiang et al. "Effect of morphological evolution of serrated chips on surface formation during high speed cutting Ti6Al4V" . (2018) : 147-150 .
APA Xu, Xiang , Zhang, Jun , Liu, Hongguang , Qi, Yutong , Liu, Zhechao , Zhao, Wanhua . Effect of morphological evolution of serrated chips on surface formation during high speed cutting Ti6Al4V . (2018) : 147-150 .
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Thermal error modeling of spindle based on the principal component analysis considering temperature-changing process EI Scopus SCIE
期刊论文 | 2018 , 99 (5-8) , 1341-1349 | International Journal of Advanced Manufacturing Technology
WoS CC Cited Count: 2 SCOPUS Cited Count: 2
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Abstract :

Thermal error is one of the most significant factors that influence the machining accuracy. Thermal error compensation is an easy and economical way to reduce the thermal error. However, the effectiveness of compensation is highly dependent on the thermal error model. In this paper, the thermal characteristics of the spindle of a horizontal machining center are investigated and tested. The measured temperature changes during a period of time are reconstructed based on PCA and used as the new input variables rather than discrete temperatures collected at some certain moments for axial spindle thermal error modeling. By comparing with the thermal error model built on original temperature data, it finds out that the accuracy of spindle thermal error modeling and prediction are improve by adopting PCA for data processing. © 2018, Springer-Verlag London Ltd., part of Springer Nature.

Keyword :

Measured temperatures Spindle systems Spindle thermal errors Temperature changing Thermal characteristic analysis Thermal characteristics Thermal error compensation Thermal error modeling

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GB/T 7714 Li, Yang , Wei, Wenming , Su, Dongxu et al. Thermal error modeling of spindle based on the principal component analysis considering temperature-changing process [J]. | International Journal of Advanced Manufacturing Technology , 2018 , 99 (5-8) : 1341-1349 .
MLA Li, Yang et al. "Thermal error modeling of spindle based on the principal component analysis considering temperature-changing process" . | International Journal of Advanced Manufacturing Technology 99 . 5-8 (2018) : 1341-1349 .
APA Li, Yang , Wei, Wenming , Su, Dongxu , Zhao, Wanhua , Zhang, Jun , Wu, Wenwu . Thermal error modeling of spindle based on the principal component analysis considering temperature-changing process . | International Journal of Advanced Manufacturing Technology , 2018 , 99 (5-8) , 1341-1349 .
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Iso-parametric path-planning method of twin-tool milling for turbine blades EI SCIE Scopus
期刊论文 | 2018 , 98 (9-12) , 3179-3189 | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
WoS CC Cited Count: 1
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Abstract :

Twin-tool milling is a new method for turbine blade machining. The dorsal and basin surfaces are machined simultaneously, which can improve the machining efficiency obviously. However, its tool path planning becomes a major challenge due to the asymmetry of the blade surfaces and the structural constraints of the twin-tool machine. In this paper, an iso-parametric path-planning method is proposed for turbine blades milling with twin tools. Considering the structural constraints, the twin-tool orientations are characterized uniformly. In order to guarantee the smoothness of the tool paths, the calculating and equally parameterized fitting algorithm for the cutter contact (CC) points in each path is proposed. Furthermore, the opposite tool paths are matched with a self-defined ratio to realize the simultaneous milling for both blade surfaces. Finally, the tool paths are planned for a typical turbine blade based on the method. The results of simulation and verification experiments show that both blade surfaces are entirely machined. The contour errors can meet the tolerance requirements. In addition, the efficiency increases by about 45% compared with the single-tool milling of the equivalent cutting parameters.

Keyword :

Iso-parametric Path-planning method Twin-tool milling Turbine blade

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GB/T 7714 Song, Dongdong , Xue, Fei , Wu, Diaodiao et al. Iso-parametric path-planning method of twin-tool milling for turbine blades [J]. | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2018 , 98 (9-12) : 3179-3189 .
MLA Song, Dongdong et al. "Iso-parametric path-planning method of twin-tool milling for turbine blades" . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 98 . 9-12 (2018) : 3179-3189 .
APA Song, Dongdong , Xue, Fei , Wu, Diaodiao , Zhang, Jun , Zhang, Xing , Zhao, Wanhua et al. Iso-parametric path-planning method of twin-tool milling for turbine blades . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2018 , 98 (9-12) , 3179-3189 .
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Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics EI SCIE Scopus
期刊论文 | 2018 , 140 (8) | JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
WoS CC Cited Count: 2 SCOPUS Cited Count: 1
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Abstract :

Five-axis machine with rotary-tilting spindle head (RTSH) is always used for sculptured surface machining, and the tool-tip dynamics in various machining postures along the tool path directly affect the machining accuracy and stability. To rapidly evaluate the tool-tip dynamics at different postures during the structural design of tool-spindle-spindle head (TSSH) assembly, this paper proposes a coupled dynamic model of tool-spindle-bearing system (TSBS) and RTSH. The model is a rigid-flexible multibody dynamic model with 36 degrees-of-freedom (DOFs), where in the rotary shaft, swivel shaft and housing are treated as rigid bodies; the tool, tool holder, and spindle shaft are modeled by reduced beams; the bearings and flexible joints are modeled as spring-damping elements. The fully Cartesian coordinates and Lagrangian method are employed to deduce a general parametric dynamic equation. The analytical method for calculating the contact stiffness of bearings and flexible joints is systematically presented, including tool-holder joint, holder-spindle joint, spindle bearings, hirth coupling, and the bearings and locking joints of rotary and swivel shafts. The model is verified by the frequency response functions (FRFs) testing and modal testing at different postures. The experimental results show that the proposed model can be used for accurate and efficient evaluation of the tool-tip FRFs, natural frequencies and mode shapes of TSSH at an arbitrary posture.

Keyword :

tool-holder-spindle rotary-tilting spindle head joint stiffness coupled dynamic model pose-dependent dynamics

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GB/T 7714 Du, Chao , Zhang, Jun , Lu, Dun et al. Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics [J]. | JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME , 2018 , 140 (8) .
MLA Du, Chao et al. "Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics" . | JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME 140 . 8 (2018) .
APA Du, Chao , Zhang, Jun , Lu, Dun , Zhang, Huijie , Zhao, Wanhua . Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics . | JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME , 2018 , 140 (8) .
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