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学者姓名：赵万华
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Abstract ：
CNC machine tools have high requirements for precision and smoothness of motion. As the power source, the performance of the servo motor has a significant impact on the movement of the machine tool. Harmonic is a common phenomenon in motors, which brings adverse effects on the performance of the motor, even the whole machine and the machined parts. Therefore, it's of great significance to study the source, characteristics, and influencing factors of the harmonics. In this paper, the time domain modeling, simulation, and analysis are carried out for the harmonic phenomenon of the surface-mounted 3-phase AC permanent magnet synchronous motor (PMSM). Firstly, a dynamic model of the servo motor integrated with its control and driving system is established under ideal conditions, and the simulation of the motor running state is realized in the time domain. On this basis, the modeling and simulation are carried out for the inverter dead-zone, cogging torque, rotor mixed-eccentricity, and 3-phase asymmetry, respectively, and the frequency components of the harmonics caused by these factors are obtained. Finally, the influence of load and motor rotational velocity on 3-phase current and torque harmonics is analyzed, and the interactions between the inverter and the motor are investigated. The results show that the inverter and the motor are coupled to each other as an integrated system, and they have impacts on each other. The established model is verified by experiments.
Keyword ：
cogging torque harmonic analysis inverter dead-zone Permanent magnet synchronous motor rotor eccentricity three-phase asymmetry
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| GB/T 7714 | Zhang, Wei , Zhang, Xing , Jin, Xiaoliang et al. Dynamic modeling and harmonic analysis of surface-mounted three-phase AC permanent magnet synchronous motor [J]. | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE , 2023 . |
| MLA | Zhang, Wei et al. "Dynamic modeling and harmonic analysis of surface-mounted three-phase AC permanent magnet synchronous motor" . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE (2023) . |
| APA | Zhang, Wei , Zhang, Xing , Jin, Xiaoliang , Zhang, Huijie , Zhao, Wanhua . Dynamic modeling and harmonic analysis of surface-mounted three-phase AC permanent magnet synchronous motor . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE , 2023 . |
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Abstract ：
Asymmetric flexibility of the machining system exists widely in the practical milling process. In this paper, a generalized milling dynamics modeling method for an asymmetric flexible 4DOF cutter-workpiece system is proposed, which is further used to reveal how the asymmetric flexi-bility affects the milling dynamics characteristics. The regenerative milling force model is firstly established through the coupling coefficient matrix, in which the milling condition with non-parallel direction between the axis directions of coordinate system, the vibration directions of system DOF and the acting directions of milling force are well handled. Then, a generalized 4DOF milling dynamics model considering a new dimension, namely the cutter and workpiece feed direction angle combination psi (psi(c), psi(w)), is presented. The studies point out that the milling dy-namics characteristics of the asymmetric flexible machining system, including the milling sta-bility and surface location error (SLE), have a significant feed direction-dependent feature. Moreover, the generation mechanism of this kind of asymmetric milling dynamics has been successfully clarified. The proposed method has been experimentally validated by a series of milling tests in an asymmetric flexible machining system. Lastly, the influences of the asymmetry degree of the system flexibility, milling type and radial depth of cut on the milling dynamics are both analyzed by numerical simulation.
Keyword ：
Asymmetric flexibility Feed direction-dependent Milling dynamics SLE Stability
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| GB/T 7714 | Zhang, Xing , Zhao, Zhao , Chen, Kunhong et al. Generalized modeling of milling dynamics for the 4DOF machining system with asymmetric flexibility [J]. | MECHANICAL SYSTEMS AND SIGNAL PROCESSING , 2022 , 169 . |
| MLA | Zhang, Xing et al. "Generalized modeling of milling dynamics for the 4DOF machining system with asymmetric flexibility" . | MECHANICAL SYSTEMS AND SIGNAL PROCESSING 169 (2022) . |
| APA | Zhang, Xing , Zhao, Zhao , Chen, Kunhong , Zhao, Wanhua . Generalized modeling of milling dynamics for the 4DOF machining system with asymmetric flexibility . | MECHANICAL SYSTEMS AND SIGNAL PROCESSING , 2022 , 169 . |
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Abstract ：
Tool wear is an important factor that affects the quality and machining accuracy of aeronautical structural parts in the milling process. It is essential to monitor the tool wear in titanium alloy machining. The traditional tool wear features such as root mean square (RMS), kurtosis, and wavelet packet energy spectrum are related to not only the tool wear status but also to the milling parameters, thus monitoring the tool wear status only under fixed milling parameters. This paper proposes a new method of online monitoring of tool wear using milling force coefficients. The instantaneous cutting force model is used to extract the milling force coefficients which are independent of milling parameters. The principal component analysis (PCA) algorithm is used to fuse the milling force coefficients. Furthermore, support vector machine (SVM) model is used to monitor tool wear states. Experiments with different machining parameters were conducted to verify the effectiveness of this method used for tool wear monitoring. The results show that compared to traditional features, the milling force coefficients are not dependent on the milling parameters, and using milling force coefficients can effectively monitor the transition point of cutters from normal wear to severe wear (tool failure).
Keyword ：
c-SVM Feature fusion Milling force coefficients Tool wear monitoring
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| GB/T 7714 | Pan, Tianhang , Zhang, Jun , Zhang, Xing et al. Milling force coefficients-based tool wear monitoring for variable parameter milling [J]. | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2022 , 120 (7-8) : 4565-4580 . |
| MLA | Pan, Tianhang et al. "Milling force coefficients-based tool wear monitoring for variable parameter milling" . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 120 . 7-8 (2022) : 4565-4580 . |
| APA | Pan, Tianhang , Zhang, Jun , Zhang, Xing , Zhao, Wanhua , Zhang, Huijie , Lu, Bingheng . Milling force coefficients-based tool wear monitoring for variable parameter milling . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2022 , 120 (7-8) , 4565-4580 . |
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Abstract ：
The thermal behaviors of the ball screw feed system significantly affect the machining accuracy of the machine tool, which is widely valued by users and manufacturers. In the current ball screws thermal error models, the moving heat source at nuts is simplified to a fixed heat source to simplify the calculation, which can decrease the model's prediction accuracy. A novel thermal error modeling method for the ball screw feed system is proposed by this paper based on the FEM. In the proposed method, the moving heat source at the nut is loaded into the model by changing the grid distribution at different time steps. Meanwhile, a series of thermal experiments are carried out to collect the thermodynamic data with the machine tool's feed drive system operating at a different speed. And then the multi-objective optimization method is introduced to obtain the heat generated by the nuts and the convection coefficient between the air and the screw. The experimental results show that the thermal error of the ball screw feed system is different when the feed system runs in different intervals, even if the temperature rise at measuring points is the same. In the final, experiments under different conditions are carried out, and the proposed model is accurate enough to predict the thermal error of the ball screw feed system.
Keyword ：
Ball screw Error modeling Feed drive system FEM Thermal error
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| GB/T 7714 | Su, Dongxu , Li, Yang , Zhao, Wanhua et al. Transient thermal error modeling of a ball screw feed system [J]. | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2022 . |
| MLA | Su, Dongxu et al. "Transient thermal error modeling of a ball screw feed system" . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY (2022) . |
| APA | Su, Dongxu , Li, Yang , Zhao, Wanhua , Zhang, Huijie . Transient thermal error modeling of a ball screw feed system . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2022 . |
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Abstract ：
Tool breakage is a prominent concern during the rough machining process, which is essential to be monitored online to prevent this phenomenon and maintain the surface quality. In this study, a tool breakage monitoring method is proposed based on the mechanism model and machining data using the acceleration signal. This method takes care of the whole process with the transition from a fresh tool to its full breakage. The mechanism of the tool breakage is obtained by this method, which is then implemented into a single synthesis parameter based on the frequency domain feature for the analysis of tool condition, and the data of fused features are statistically processed to carry out the breakage monitoring. The parameter 37 (three times the mean of standard deviation) is taken as the threshold value to determine the breakage condition in real time. The experimental results are in good agreement with the theoretical model, which proves the efficiency and simplicity of online tool breakage monitoring based on the proposed method.
Keyword ：
Acceleration signal Milling force Real-time monitoring Statistical analysis method Tool breakage
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| GB/T 7714 | Pan, Tianhang , Zhang, Jun , Yang, Lei et al. Tool breakage monitoring based on the feature fusion of spindle acceleration signal [J]. | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2021 , 117 (9-10) : 2973-2986 . |
| MLA | Pan, Tianhang et al. "Tool breakage monitoring based on the feature fusion of spindle acceleration signal" . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 117 . 9-10 (2021) : 2973-2986 . |
| APA | Pan, Tianhang , Zhang, Jun , Yang, Lei , Zhao, Wanhua , Zhang, Huijie , Lu, Bingheng . Tool breakage monitoring based on the feature fusion of spindle acceleration signal . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2021 , 117 (9-10) , 2973-2986 . |
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Abstract ：
High efficiency and high precision milling, as the eternal goal of CNC machining, needs to balance many constraints for selecting the most reasonable processing parameters. This paper presents an efficient machining parameter optimization method for finishing milling operation with multiple constraints. Firstly, under the multiple constraints of parameter feasible region, milling force, milling stability, roughness, and machining contour accuracy, a multi-variable parameter optimization model with machining efficiency as the objective is established. A four level cycle optimization strategy has been detailly described for solving the optimization problem, in which the feed per tooth is optimized by using the golden section method, and with the aid of the random vector search method, the spindle speed, radial, and axial depth cuts are both numerically iterated. The optimal machining parameter combination of the tooth number, feed per tooth, spindle speed, radial, and axial depth of cuts are achieved at last. Finally, the experimental verification results show that the proposed method can greatly improve the machining efficiency under chatter free condition and achieve an efficient finishing milling with consideration of the multiple constraints.
Keyword ：
chatter free Milling milling force multiple constraints parameter optimization
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| GB/T 7714 | Zhang, Xing , Zhao, Zhao , Guo, Zhuocheng et al. Research on machining parameter optimization in finishing milling with multiple constraints [J]. | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE , 2021 , 236 (6-7) : 968-980 . |
| MLA | Zhang, Xing et al. "Research on machining parameter optimization in finishing milling with multiple constraints" . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE 236 . 6-7 (2021) : 968-980 . |
| APA | Zhang, Xing , Zhao, Zhao , Guo, Zhuocheng , Zhao, Wanhua . Research on machining parameter optimization in finishing milling with multiple constraints . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE , 2021 , 236 (6-7) , 968-980 . |
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Abstract ：
The feed system is affected by multi-source and multi-frequency disturbances in the actual milling process of the machine tool, especially the direct-drive feed system due to the zero transmission, the motion accuracy is more significantly affected by external disturbances. The disturbance mechanism, frequency spectrum characteristics and linear motor feed system thrust current spectrum characteristics are investigated. Comprehensively considering the multi-source disturbance of tool-spindle system during the milling process, the milling force model, spindle centrifugal force model, spindle bearing vibration model are established and the corresponding multi-source disturbance spectrum characteristics are analyzed. The displacement fluctuation characteristics of linear motor feed system under multi-source disturbance excitation are characterized, and single-axis feed cutting experiment is completed on VMC0865 machine tool driven by a linear motor. The experimental results show that as the feed speed is 1 500 mm/min, spindle speed is 5 000 r/min, cutting width is 2 mm, and cutting depth is 2 mm, the mean square value of X-axis displacement fluctuation increases from 0.36 μm to 0.81 μm, and the mean square value of thrust current increases from 0.94 A to 1.15 A; the thrust current heightens the harmonic components of the spindle frequency and its multiplication, division and side frequencies; cutting force affects motion accuracy of the feed system, thereby lowers the quality and accuracy of the part processing. The influence of the process on the spectral characteristics of thrust current of linear motor feed system and the influence of different cutting parameters on the spectral characteristics of thrust current are comparatively analyzed. It is obvious that spindle speed is the most significant cutting parameter for spectral characteristics of thrust current. © 2021, Editorial Office of Journal of Xi'an Jiaotong University. All right reserved.
Keyword ：
Cutting Linear motors Machine tool drives Machine tools Milling (machining) Turning Vibration analysis
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| GB/T 7714 | Quan, Li , Zhao, Wanhua . Linear Motor Thrust Current Spectrum Characteristics Under Influence of Multi-Source Disturbance in Milling Process [J]. | Journal of Xi'an Jiaotong University , 2021 , 55 (4) : 8-19 . |
| MLA | Quan, Li et al. "Linear Motor Thrust Current Spectrum Characteristics Under Influence of Multi-Source Disturbance in Milling Process" . | Journal of Xi'an Jiaotong University 55 . 4 (2021) : 8-19 . |
| APA | Quan, Li , Zhao, Wanhua . Linear Motor Thrust Current Spectrum Characteristics Under Influence of Multi-Source Disturbance in Milling Process . | Journal of Xi'an Jiaotong University , 2021 , 55 (4) , 8-19 . |
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Abstract ：
Chatter monitoring is an important task while ensuring machining quality and improving machining efficiency. Under variable cutting conditions, cutting parameters often change, and the cutting state and traditional time-frequency domain cutting features will also change significantly. In order to achieve precise monitoring of chatter under such cutting conditions, this article proposes a time series method named recurrence plot (RP) that can reflect the non-stationary characteristics and state differences of the signal system to analyze the cutting force signal in the cutting process. Firstly, reconstruct the phase space, generate RP; then use recurrence quantitative analysis (RQA) to extract statistical features in the RP that reflect the current state of the system; thirdly, use affinity propagation (AP) clustering method to find out the exemplar features from the RQA; finally, train the exemplar features using the light gradient boosting (LGB) method to obtain the classification prediction model. Experimental results show that this method can effectively identify the machining chatter state and stable cutting state under variable cutting conditions. © 2021, The Author(s), under exclusive licence to Springer-Verlag London Ltd. part of Springer Nature.
Keyword ：
Cluster analysis Frequency domain analysis Milling (machining) Phase space methods Predictive analytics Signal systems Time series
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| GB/T 7714 | Chen, Kunhong , Zhang, Xing , Zhao, Zhao et al. Milling chatter monitoring under variable cutting conditions based on time series features [J]. | International Journal of Advanced Manufacturing Technology , 2021 , 113 (9-10) : 2595-2613 . |
| MLA | Chen, Kunhong et al. "Milling chatter monitoring under variable cutting conditions based on time series features" . | International Journal of Advanced Manufacturing Technology 113 . 9-10 (2021) : 2595-2613 . |
| APA | Chen, Kunhong , Zhang, Xing , Zhao, Zhao , Yin, Jia , Zhao, Wanhua . Milling chatter monitoring under variable cutting conditions based on time series features . | International Journal of Advanced Manufacturing Technology , 2021 , 113 (9-10) , 2595-2613 . |
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Abstract ：
Difficult-to-cut materials are widely used in aerospace and other industries. Titanium alloys are the most popular ones among them due to their high strength-to-weight ratio and high temperature resistance. However, in high-speed machining, the alloys are prone to produce serrated chips, which have a serious influence on surface integrity. In this study, a coupled Eulerian-Lagrangian method is used to simulate the orthogonal cutting of Ti6Al4V due to its advantages of avoiding element distortion and improving the data extraction efficiency. The internal relationship between serrated chip formation and periodic profile of machined surfaces is analyzed by the simulation results and experimental data which are obtained by optical microscope and white light interferometer. Furthermore, thermal-mechanical loads on machined surfaces are reconstructed based on the simulation results, and a coupled finite element and cellular automata approach is used to describe the dynamic recrystallization process within the area of the machined surface during the formation of a single serration. According to the results, the periodic fluctuation of cutting forces is attributed to the serrated chip formation phenomenon, which then leads to the periodic profile of machined surfaces. The period is about 60-70 µm, and its amplitude decreases with the increase of cutting speeds. Moreover, the loads on machined surfaces also show the same period due to serrated chip formation. As a result, the grain refinement layer thickness (about 2 ∼ 5 µm) in machined surfaces is related to the surface temperature and exhibits the same periodic characteristics along the cutting direction. Copyright © 2021 by ASME
Keyword ：
Aerospace industry Aluminum alloys Aluminum metallography Cellular automata Cutting Dynamic recrystallization Grain refinement High strength alloys Lagrange multipliers Machining Ternary alloys Titanium alloys Titanium metallography Vanadium alloys Vanadium metallography
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| GB/T 7714 | Xu, Binbin , Zhang, Jun , Liu, Hongguang et al. Serrated chip formation induced periodic distribution of morphological and physical characteristics in machined surface during high-speed machining of Ti6Al4V [J]. | Journal of Manufacturing Science and Engineering, Transactions of the ASME , 2021 , 143 (10) . |
| MLA | Xu, Binbin et al. "Serrated chip formation induced periodic distribution of morphological and physical characteristics in machined surface during high-speed machining of Ti6Al4V" . | Journal of Manufacturing Science and Engineering, Transactions of the ASME 143 . 10 (2021) . |
| APA | Xu, Binbin , Zhang, Jun , Liu, Hongguang , Xu, Xiang , Zhao, Wanhua . Serrated chip formation induced periodic distribution of morphological and physical characteristics in machined surface during high-speed machining of Ti6Al4V . | Journal of Manufacturing Science and Engineering, Transactions of the ASME , 2021 , 143 (10) . |
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Abstract ：
For an efficient and precise machining of spiral gear, the special face-milling process for spiral bevel gear is developed and widely used, exhibiting great difference from the general milling process in cutting machine, cutter and cutting kinematics. The un-deformed chip geometry, cutting force model and regenerating mechanism are hence complexly different, bringing great challenge to the modeling of cutting dynamics. In this regard, no relevant work can be found at present. To overcome this problem, through fully investigating the cutting force regenerating mechanism under complicated cutting kinematics, this paper first develops an analytical cutting force prediction model by classifying the chip geometry into 6 cases, and then a simplified dynamic chip model by assuming the chip geometry cases unchanged and ignoring edge alteration. On such basis, the model for prediction of the cutting dynamics and the chatter stability are developed and validated. Besides, the 3D stability lobe for face-milling of spiral bevel gear is presented and the cutting system tends to be stable with high cutter gear ratio and cutting speed. © 2020 Elsevier Ltd
Keyword ：
Bevel gears Dynamics Gear cutting Geometry Kinematics Milling (machining) Predictive analytics
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| GB/T 7714 | Zheng, Fangyan , Han, Xinghui , Lin, Hua et al. Research on the cutting dynamics for face-milling of spiral bevel gears [J]. | Mechanical Systems and Signal Processing , 2021 , 153 . |
| MLA | Zheng, Fangyan et al. "Research on the cutting dynamics for face-milling of spiral bevel gears" . | Mechanical Systems and Signal Processing 153 (2021) . |
| APA | Zheng, Fangyan , Han, Xinghui , Lin, Hua , Zhao, Wanhua . Research on the cutting dynamics for face-milling of spiral bevel gears . | Mechanical Systems and Signal Processing , 2021 , 153 . |
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