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学者姓名:赵万华

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Serrated chip formation induced periodic distribution of morphological and physical characteristics in machined surface during high-speed machining of Ti6Al4V EI SCIE
期刊论文 | 2021 , 143 (10) | Journal of Manufacturing Science and Engineering, Transactions of the ASME
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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 :

Vanadium metallography High strength alloys Machining Ternary alloys Vanadium alloys Cellular automata Cutting Aerospace industry Aluminum alloys Lagrange multipliers Grain refinement Titanium metallography Aluminum metallography Titanium alloys Dynamic recrystallization

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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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Milling chatter monitoring under variable cutting conditions based on time series features EI SCIE
期刊论文 | 2021 , 113 (9-10) , 2595-2613 | International Journal of Advanced Manufacturing Technology
WoS CC Cited Count: 1
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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 :

Milling (machining) Phase space methods Signal systems Frequency domain analysis Predictive analytics Cluster analysis 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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Tool breakage monitoring based on the feature fusion of spindle acceleration signal SCIE
期刊论文 | 2021 , 117 (9-10) , 2973-2986 | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
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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 Real-time monitoring Tool breakage Milling force Statistical analysis method

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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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Acceleration-Dependent Analysis of Vertical Ball Screw Feed System without Counterweight EI SCIE
期刊论文 | 2021 , 34 (1) | Chinese Journal of Mechanical Engineering (English Edition)
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Abstract :

The distinguishing feature of a vertical ball screw feed system without counterweight is that the spindle system weight directly acts on the kinematic joints. Research into the dynamic characteristics under acceleration and deceleration is an important step in improving the structural performance of vertical milling machines. The magnitude and direction of the inertial force change significantly when the spindle system accelerates and decelerates. Therefore, the kinematic joint contact stiffness changes under the action of the inertial force and the spindle system weight. Thus, the system transmission stiffness also varies and affects the dynamics. In this study, a variable-coefficient lumped parameter dynamic model that considers the changes in the spindle system weight and the magnitude and direction of the inertial force is established for a ball screw feed system without counterweight. In addition, a calculation method for the system stiffness is provided. Experiments on a vertical ball screw feed system under acceleration and deceleration with different accelerations are also performed to verify the proposed dynamic model. Finally, the influence of the spindle system position, the rated dynamic load of the screw-nut joint, and the screw tension force on the natural frequency of the vertical ball screw feed system under acceleration and deceleration are studied. The results show that the vertical ball screw feed system has obviously different variable dynamics under acceleration and deceleration. The influence of the rated dynamic load and the spindle system position on the natural frequency under acceleration and deceleration is much greater than that of the screw tension force. © 2021, The Author(s).

Keyword :

Natural frequencies Stiffness Milling (machining) Ball screws Dynamic models Kinematics Deceleration Acceleration Dynamic loads

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GB/T 7714 Zou, Cunfan , Zhang, Huijie , Zhang, Jun et al. Acceleration-Dependent Analysis of Vertical Ball Screw Feed System without Counterweight [J]. | Chinese Journal of Mechanical Engineering (English Edition) , 2021 , 34 (1) .
MLA Zou, Cunfan et al. "Acceleration-Dependent Analysis of Vertical Ball Screw Feed System without Counterweight" . | Chinese Journal of Mechanical Engineering (English Edition) 34 . 1 (2021) .
APA Zou, Cunfan , Zhang, Huijie , Zhang, Jun , Song, Dongdong , Liu, Hui , Zhao, Wanhua . Acceleration-Dependent Analysis of Vertical Ball Screw Feed System without Counterweight . | Chinese Journal of Mechanical Engineering (English Edition) , 2021 , 34 (1) .
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Linear Motor Thrust Current Spectrum Characteristics Under Influence of Multi-Source Disturbance in Milling Process EI
期刊论文 | 2021 , 55 (4) , 8-19 | Journal of Xi'an Jiaotong University
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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 :

Machine tool drives Machine tools Milling (machining) Cutting Vibration analysis Turning Linear motors

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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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Research on machining parameter optimization in finishing milling with multiple constraints SCIE
期刊论文 | 2021 | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
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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 :

Milling parameter optimization multiple constraints chatter free milling force

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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 .
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 (2021) .
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 .
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Research on the cutting dynamics for face-milling of spiral bevel gears EI SCIE
期刊论文 | 2021 , 153 | Mechanical Systems and Signal Processing
WoS CC Cited Count: 1
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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 :

Milling (machining) Dynamics Geometry Kinematics Predictive analytics Bevel gears Gear cutting

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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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Selection method of CNC machine tools based on big data cloud database EI
会议论文 | 2020 , 391-394 | 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020
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Abstract :

Parts from design models to actual entities generally are achieved by machining. And the machining accuracy rely on the choice of CNC machine tool. However, it is hard to predict whether the choice of machine tool is reasonable and whether it can complete the machining efficiently on the premise of satisfying the accuracy requirement. In this study a method based on a machine tools big data was proposed to select the machine tools. A machine tool big data cloud database was built to collect and upload the data through identification experiment of candidate machine tool. The actual position prediction method of the feed shaft for five-axis machining and the solving method of the contour error for the part were established respectively.The actual position of the feed shaft for five-axis machining is predicted by using the big data cloud database to establish the transfer function of each axis for the machine tool, and the actual position of each axis is predicted by inputting the interpolation instruction of each axis into the transfer function.The solving method of the contour error for the part is established by using the big data cloud database to synthesize the interpolation instruction and predicted actual position of each axis, and then to calculate the contour error of the part. The new method proposed herein can choose the optimal CNC machine tool with high efficiency and accuracy. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

Keyword :

Nanotechnology Machine tools Big data Machining Computer control systems Interpolation Errors Precision engineering Turing machines Database systems

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GB/T 7714 Liu, Qing , Lyu, Dun , Zhao, Wanhua . Selection method of CNC machine tools based on big data cloud database [C] . 2020 : 391-394 .
MLA Liu, Qing et al. "Selection method of CNC machine tools based on big data cloud database" . (2020) : 391-394 .
APA Liu, Qing , Lyu, Dun , Zhao, Wanhua . Selection method of CNC machine tools based on big data cloud database . (2020) : 391-394 .
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Gain Design Method of Machine Tool Contour Controllers Based on Stability Margin EI CSCD
期刊论文 | 2020 , 31 (13) , 1513-1517 | China Mechanical Engineering
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The contour controllers were usually designed as a P controller, and the gain value was the key parameter to determine the control effectiveness. In order to design the gain values of contour controllers quantitatively, a gain design method of contour controllers was proposed based on stability margin herein. Firstly, the discrete transfer functions of each axis of the machine tool were identified by applying the least squares method. Secondly, the stability domain of the gain was calculated based on the Jury criterion and transfer functions. Finally, the objective function was constructed, and the gain values satisfying the stability margin requirements were obtained in the stability domain. A contour controller was designed on a three-axis machine tool, and a trajectory tracking experiment was carried out to verify the effectiveness of the proposed method. The experimental results show that the contour controller designed based on stability margin may reduce the maximum trajectory error of the spiral trajectory by 39.06% and the maximum trajectory error of the fan-shaped trajectory by 34.33%, under the conditions of ensuring the motion stability of the machine tools. © 2020, China Mechanical Engineering Magazine Office. All right reserved.

Keyword :

Least squares approximations Stability Controllers Machine tools Trajectories Transfer functions Design

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GB/T 7714 Zhan, Chengpeng , Yang, Lei , Yang, Xiao et al. Gain Design Method of Machine Tool Contour Controllers Based on Stability Margin [J]. | China Mechanical Engineering , 2020 , 31 (13) : 1513-1517 .
MLA Zhan, Chengpeng et al. "Gain Design Method of Machine Tool Contour Controllers Based on Stability Margin" . | China Mechanical Engineering 31 . 13 (2020) : 1513-1517 .
APA Zhan, Chengpeng , Yang, Lei , Yang, Xiao , Zhao, Wanhua . Gain Design Method of Machine Tool Contour Controllers Based on Stability Margin . | China Mechanical Engineering , 2020 , 31 (13) , 1513-1517 .
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Hybrid modeling and analysis of multidirectional variable stiffness of the linear rolling guideway under combined loads EI SCIE
期刊论文 | 2020 , 234 (13) , 2716-2727 | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE | IF: 1.762
WoS CC Cited Count: 1
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Abstract :

In the working process of high-speed multiaxis machine tools, inertial loads due to high feed acceleration and time-varying gravity loads due to changing configuration of multiaxis structure result in time-varying complex loads applied to linear rolling guideway. Existing models cannot efficiently represent the effect of complex loads on multidirectional stiffness variation of linear rolling guideway. In this paper, a hybrid model of multidirectional stiffness of linear rolling guideway and the solving algorithm are proposed. The complex loading conditions of linear rolling guideway in high-speed multiaxis machine tool structure are considered. And contact flexibilities between rolling balls and grooves are modeled with the effect of elastic deformations of runner block and rail. The proposed model can calculate the multidirectional stiffness with high accuracy. Meanwhile the differences between the stiffness characteristics in different directions are represented correctly. The variations of multidirectional stiffness of linear rolling guideway under time-varying combined loads are analyzed. This study provides an effective way to comprehensively evaluate the stiffness characteristics of linear rolling guideway which can contribute to the dynamic analysis and active design of high-speed machine tool structure.

Keyword :

hybrid model Linear rolling guideway multidirectional stiffness combined loads multiaxis machine tools

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GB/T 7714 Yang, Lei , Wang, Lei , Zhao, Wanhua . Hybrid modeling and analysis of multidirectional variable stiffness of the linear rolling guideway under combined loads [J]. | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE , 2020 , 234 (13) : 2716-2727 .
MLA Yang, Lei et al. "Hybrid modeling and analysis of multidirectional variable stiffness of the linear rolling guideway under combined loads" . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE 234 . 13 (2020) : 2716-2727 .
APA Yang, Lei , Wang, Lei , Zhao, Wanhua . Hybrid modeling and analysis of multidirectional variable stiffness of the linear rolling guideway under combined loads . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE , 2020 , 234 (13) , 2716-2727 .
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