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Feedback linearization and equivalent-disturbance compensation control strategy for piezoelectric stage

Nanotechnology and Precision Engineering 2024年第2期7卷 49-59页

作者： Tao Huang Yingbin Wang Zhihong Luo huajun cao Guibao Tao Mingxiang Ling State Key Laboratory of Mechanical Transmissions for Advanced Equipment Chongqing UniversityChongqing 400044China College of Mechanical and Vehicle Engineering Chongqing UniversityChongqing 400044China Hongdu Aviation Industry Group NanchangJiangxi 330000China Robotics and Microsystems Center Soochow UniversitySuzhou 215123China

Piezoelectric stages use piezoelectric actuators and flexure hinges as driving and amplifying mechanisms,respectively.These systems have high positioning accuracy and high-frequency responses,and they are widely used in various precision/ultra-precision positioning fields.However,the main challenge with these devices is the inherent hysteresis nonlinearity of piezoelectric actuators,which seriously affects the tracking accuracy of a piezoelectric stage.Inspired by this challenge,in this work,we developed a Hammerstein model to describe the hysteresis nonlinearity of a piezoelectric stage.In particular,in our proposed scheme,a feedback-linearization algorithm is used to eliminate the static hysteresis nonlinearity.In addition,a composite controller based on equivalent-disturbance compensation was designed to counteract model uncertainties and external disturbances.An analysis of the stability of a closed-loop system based on this feedback-linearization algorithm and composite controller was performed,and this was followed by extensive comparative experiments using a piezoelectric stage developed in the laboratory.The experimental results confirmed that the feedback-linearization algorithm and the composite controller offer improved linearization and trajectory-tracking performance.

关键词： Piezoelectric stage Hysteresis nonlinearity Feedback linearization Equivalent-disturbance compensation

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Model of Surface Texture for Honed Gear Considering Motion Path and Geometrical Shape of Abrasive Particle

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Chinese Journal of Mechanical Engineering 2023年第4期36卷 311-325页

作者： Yuhu Liu Xiaohui Huang huajun cao Jiacheng Wang Huapan Xiao College of Mechanical and Vehicle Engineering Chongqing UniversityChongqing 400044China State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China

Gear power-honing is mainly applied to finish small and medium-sized automotive gears,especially in new energy vehicles.The distinctive curved surface texture greatly improves the noise emission and service life of honed gears.The surface texture for honed gear considering the motion path and geometrical shape of abrasive particles has not been investigated.In this paper,the kinematics of the gear honing process is analyzed,and the machining marks produced by the abrasive particles of honing wheel scratching abrasive particles against the workpiece gear are calculated.The tooth surface roughness is modeled considering abrasive particle shapes and material plastic pile-ups.This results in a mathematical model that characterizes the structure of the tooth surface and the orientation of the machining marks.Experiments were used to verify the model,with a maximum relative error of less than 10%when abrasive particles are spherical.Based on this model,the effects of process parameters on the speeds of discrete points on the tooth flank,orientations of machining marks and roughness are discussed.The results show that the shaft angle between the workpiece gear and the honing wheel and the speed of the honing wheel is the main process parameters affecting the surface texture.This research proposes a surface texture model for honed gear,which can provide a theoretical basis for optimizing process parameters for gear power-honing.

关键词： Hardened gear Gear power-honing Surface texture Roughness

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Coupling evaluation for material removal and thermal control on precision milling machine tools

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Frontiers of Mechanical Engineering 2022年第1期17卷 70-82页

作者： Kexu LAI huajun cao Hongcheng LI Benjie LI Disheng HUANG State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China School of Advanced Manufacturing Engineering Chongqing University of Posts and TelecommunicationChongqing 400065China College of Mechatronic Engineering Southwest Petroleum UniversityChengdu 610500China

Machine tools are one of the most representative machining systems in manufacturing.The energy consumption of machine tools has been a research hotspot and frontier for green low-carbon manufacturing.However,previous research merely regarded the material removal(MR)energy as useful energy consumption and ignored the useful energy consumed by thermal control(TC)for maintaining internal thermal stability and machining accuracy.In pursuit of energy-efficient,high-precision machining,more attention should be paid to the energy consumption of TC and the coupling relationship between MR and TC.Hence,the cutting energy efficiency model considering the coupling relationship is established based on the law of conservation of energy.An index of energy consumption ratio of TC is proposed to characterize its effect on total energy usage.Furthermore,the heat characteristics are analyzed,which can be adopted to represent machining accuracy.Experimental study indicates that TC is the main energy-consuming process of the precision milling machine tool,which overwhelms the energy consumption of MR.The forced cooling mode of TC results in a 7%reduction in cutting energy efficiency.Regression analysis shows that heat dissipation positively contributes 54.1%to machining accuracy,whereas heat generation negatively contributes 45.9%.This paper reveals the coupling effect of MR and TC on energy efficiency and machining accuracy.It can provide a foundation for energyefficient,high-precision machining of machine tools.

关键词： machine tools cutting energy efficiency thermal stability machining accuracy coupling evaluation

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Development and testing of a wireless smart toolholder with multi-sensor fusion

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Frontiers of Mechanical Engineering 2023年第4期18卷 131-148页

作者： Jin ZHANG Xinzhen KANG Zhengmao YE Lei LIU Guibao TAO huajun cao College of Mechanical and Vehicle Engineering Chongqing UniversityChongqing 400044China State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China Aerospace Research Institute of Materials&Processing Technology Beijing 100076China

The smart toolholder is the core component in the development of intelligent and precise manufacturing.It enables in situ monitoring of cutting data and machining accuracy evolution and has become a focal point in academic research and industrial applications.However,current table and rotational dynamometers for milling force,vibration,and temperature testing suffer from cumbersome installation and provide only a single acquisition signal,which limits their use in laboratory settings.In this study,we propose a wireless smart toolholder with multi-sensor fusion for simultaneous sensing of milling force,vibration,and temperature signals.We select force,vibration,and temperature sensors suitable for smart toolholder fusion to adapt to the cutting environment.Thereafter,structural design,circular runout,dynamic balancing,static stiffness,and dynamic inherent frequency tests are conducted to assess its dynamic and static performance.Finally,the smart toolholder is tested for accuracy and repeatability in terms of force,vibration,and temperature.Experimental results demonstrate that the smart toolholder accurately captures machining data with a relative deviation of less than 1.5%compared with existing force gauges and provides high repeatability of milling temperature and vibration signals.Therefore,it is a smart solution for machining condition monitoring.

关键词： wireless smart toolholder multi-sensor fusion circular runout dynamic balancing static stiffness dynamic inherent frequency

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Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

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机械工程前沿:英文版 2023年第2期18卷 33-97页

作者： Jin ZHANG Xuefeng HUANG Xinzhen KANG Hao YI Qianyue WANG huajun cao College of Mechanical and Vehicle Engineering Chongqing UniversityChongqing 400044China State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China

Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials,such as poor machinability,low cutting efficiency,and high energy consumption.High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids.However,the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials.The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing,making it a focus of academic and industrial research.In this review,the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials,including titanium alloys,nickel-based alloys,and high-strength steel,are systematically explored.The laser energy field,ultrasonic energy field,and cryogenic minimum quantity lubrication energy fields are introduced.By analyzing the effects of changing the energy field and cutting parameters on tool wear,chip morphology,cutting force,temperature,and surface quality of the workpiece during milling,the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated.Finally,the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail,providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

关键词： difficult-to-machine metal material green machining high-speed dry milling laser energy fieldassisted milling ultrasonic energy field-assisted milling cryogenic minimum quantity lubrication energy field-assisted milling

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Hybrid post-processing effects of magnetic abrasive finishing and heat treatment on surface integrity and mechanical properties of additively manufactured Inconel 718 superalloys

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Journal of Materials Science & Technology 2022年第33期128卷 10-21页

作者： Kun Li Ruijin Ma Ming Zhang Wen Chen Xiaobin Li David Z.Zhang Qian Tang Lawrence E.Murr Jinfeng Li huajun cao State Key Laboratory of Mechanical Transmission Chongqing UniversityChongqing 400044China Chongqing Key Laboratory of Metal Additive Manufacturing(3D Printing) Chongqing UniversityChongqing 400044China College of Engineering Mathematics and Physical SciencesUniversity of ExeterNorth Park RoadExeter EX44QFUK W.M.Keck Center for 3D Innovation University of Texas at El PasoEl PasoTX 79968USA Department of Metallurgical Materials and Biomedical EngineeringUniversity of Texas at El PasoEl PasoTX 79968USA Institute of Materials China Academy of Engineering PhysicsMianyang 621908China

Desired microstructure and surface integrity are critical to achieving the high performance of additively manufactured components.In the present work,the hybrid post-processes of magnetic abrasive finishing(MAF)and post-heat treatment(HT)were applied to the additively manufactured Inconel718 superalloys.Their hybrid effects and influencing mechanism on the surface quality and mechanical properties of the additively manufactured samples have been studied comparatively.The results show that the MAF process effectively reduces the surface roughness by more than an order of magnitude due to the flexibility and geometric consistency of the magnetic particles and abrasives with the finished surfaces.The proper sequence of MAF and HT obtains enhanced mechanical properties for the homogenized-MAF-aged sample with the yield strength of 1147 MPa,the ultimate tensile strength of 1334 MPa,and the elongation of 22.9%,which exceeds the standard wrought material.The surface integrity,compressive residual stress field,and grain refinement induced by the MAF and subsequent aging heat treatment increase the cracking resistance and delay the fracture failure,which significantly benefits the mechanical properties.The MAF process combined with proper post-heat treatment provides an effective pathway to improve the mechanical properties of additively manufactured materials.

关键词： Magnetic abrasive finishing Additive manufacturing Inconel 718 Microstructure–property relationship Heat treatment

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Assessment of fatigue life of remanufactured impeller based on FEA

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Frontiers of Mechanical Engineering 2016年第3期11卷 219-226页

作者： Lei XU huajun cao Hailong LIU Yubo ZHANG The State Key Laboratory of Mechanical Transmission Chongqing University Chongqing 400030 China National Key Laboratory for Remanufacturing Academy of Armored Forces Engineering Beijing 100072 China

Predicting the fatigue life of remanufactured centrifugal compressor impellers is a critical problem. In this paper, the S-N curve data were obtained by combining experimentation and theory deduction. The load spectrum was compiled by the rain-flow counting method based on the comprehensive consideration of the centrifugal force, residual stress, and aerodynamic loads in the repair region. A fatigue life simulation model was built, and fatigue life was analyzed based on the fatigue cumulative damage rule. Although incapable of providing a high-precision predic- tion, the simulation results were useful for the analysis of fatigue life impact factors and fatigue fracture areas. Results showed that the load amplitude greatly affected fatigue life, the impeller was protected from running at over-speed, and the predicted fatigue life was satisfied within the next service cycle safely at the rated speed.

关键词： remanufactured impeller fatigue life impeller failures finite element analysis （FEA）

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Fiber-reinforced composites in milling and grinding:machining bottlenecks and advanced strategies

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Frontiers of Mechanical Engineering 2022年第2期17卷 1-35页

作者： Teng GAO Yanbin ZHANG Changhe LI Yiqi WANG Yun CHEN Qinglong AN Song ZHANG Hao Nan LI huajun cao Hafiz Muhammad ALI Zongming ZHOU Shubham SHARMA School of Mechanical and Automotive Engineering Qingdao University of TechnologyQingdao 266520China School of Mechanical Engineering Dalian University of TechnologyDalian 116024China Chengdu Tool Research Institute Co. Ltd.Chengdu 610500China School of Mechanical Engineering Shanghai Jiao Tong UniversityShanghai 200240China School of Mechanical Engineering Shandong UniversityJinan 250061China School of Aerospace University of Nottingham Ningbo ChinaNingbo 315100China School of Mechanical Engineering Chongqing UniversityChongqing 400044China Mechanical Engineering Department King Fahd University of Petroleum and MineralsDhahran 31261Saudi Arabia Hanergy(Qingdao)Lubrication Technology Co. Ltd.Qingdao 266100China Department of Mechanical Engineering IK Gujral Punjab Technical UniversityPunjab 144603India

Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight.The composite components are manufactured by near netshape and only require finishing operations to achieve final dimensional and assembly tolerances.Milling and grinding arise as the preferred choices because of their precision processing.Nevertheless,given their laminated,anisotropic,and heterogeneous nature,these materials are considered difficult-to-machine.As undesirable results and challenging breakthroughs,the surface damage and integrity of these materials is a research hotspot with important engineering significance.This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature.First,the formation mechanisms of milling damage,including delamination,burr,and tear,are analyzed.Second,the grinding mechanisms,covering material removal mechanism,thermal mechanical behavior,surface integrity,and damage,are discussed.Third,suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies,including ultrasonic vibration-assisted machining,cryogenic cooling,minimum quantity lubrication(MQL),and tool optimization design.Ultrasonic vibration shows the greatest advantage of restraining machining force,which can be reduced by approximately 60%compared with conventional machining.Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%.MQL shows its advantages in terms of reducing friction coefficient,force,temperature,and tool wear.Finally,research gaps and future exploration directions are prospected,giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

关键词： milling grinding fiber-reinforced composites damage formation mechanism delamination material removal mechanism surface integrity minimum quantity lubrication

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Biological Stability of Water-Based Cutting Fluids:Progress and Application

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Chinese Journal of Mechanical Engineering 2022年第1期35卷 7-30页

作者： Lizhi Tang Yanbin Zhang Changhe Li Zongming Zhou Xiaolin Nie Yun Chen huajun cao Bo Liu Naiqing Zhang Zafar Said Sujan Debnath Muhammad Jamil Hafiz Muhammad Ali Shubham Sharma School of Mechanical and Automotive Engineering Qingdao University of TechnologyQingdao 266520China Hanergy(Qingdao)Lubrication Technology Co. Ltd.Qingdao 266200China Nanjing Kerun Lubricants Co. Ltd.Nanjing 211106China Chengdu Tool Research Institute Co. LtdChengdu 610500China School of Mechanical Engineering Chongqing UniversityChongqing 400044China Sichuan Future Aerospace Industry LLC Shifang 618400China Shanghai Jinzhao Energy Saving Technology Co. Ltd.Shanghai 200436China Department of Sustainable and Renewable Energy Engineering University of Sharjah27272 SharjahUnited Arab Emirates Mechanical Engineering Department Curtin University98009 MiriMalaysia College of Mechanical and Electrical Engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China Mechanical Engineering Department King Fahd University of Petroleum and MineralsDhahran 31261Saudi Arabia Department of Mechanical Engineering IK Gujral Punjab Technical UniversityKapurthala 144603PunjabIndia

The application of cutting fluid in the field of engineering manufacturing has a history of hundreds of years,and it plays a vital role in the processing efficiency and surface quality of parts.Among them,water-based cutting fluid accounts for more than 90%of the consumption of cutting fluid.However,long-term recycling of water-based cutting fluid could easily cause deterioration,and the breeding of bacteria could cause the cutting fluid to fail,increase manufacturing costs,and even endanger the health of workers.Traditional bactericides could improve the biological stability of cutting fluids,but they are toxic to the environment and do not conform to the development trend of low-carbon manufacturing.Low-carbon manufacturing is inevitable and the direction of sustainable manufacturing.The use of nanomaterials,transition metal complexes,and physical sterilization methods on the bacterial cell membrane and genetic material could effectively solve this problem.In this article,the mechanism of action of additives and microbial metabolites was first analyzed.Then,the denaturation mechanism of traditional bactericides on the target protein and the effect of sterilization efficiency were summarized.Further,the mechanism of nanomaterials disrupting cell membrane potential was discussed.The effects of lipophilicity and the atomic number of transition metal complexes on cell membrane penetration were also summarized,and the effects of ultraviolet rays and ozone on the destruction of bacterial genetic material were reviewed.In other words,the bactericidal performance,hazard,degradability,and economics of various sterilization methods were comprehensively evaluated,and the potential development direction of improving the biological stability of cutting fluid was proposed.

关键词： Cutting fluid Microorganism Bactericide Sterilization

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An energy consumption prediction approach of die casting machines driven by product parameters

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Frontiers of Mechanical Engineering 2021年第4期16卷 868-886页

作者： Erheng CHEN Hongcheng LI huajun cao Xuanhao WEN State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China School of Advanced Manufacturing Engineering Chongqing University of Posts and TelecommunicationChongqing 400065China

Die casting machines,which are the core equipment of the machinery manufacturing industry,consume great amounts of energy.The energy consumption prediction of die casting machines can support energy consumption quota,process parameter energy-saving optimization,energy-saving design,and energy efficiency evaluation;thus,it is of great significance for Industry 4.0 and green manufacturing.Nevertheless,due to the uncertainty and complexity of the energy consumption in die casting machines,there is still a lack of an approach for energy consumption prediction that can provide support for process parameter optimization and product design taking energy efficiency into consideration.To fill this gap,this paper proposes an energy consumption prediction approach for die casting machines driven by product parameters.Firstly,the system boundary of energy consumption prediction is defined,and subsequently,based on the energy consumption characteristics analysis,a theoretical energy consumption model is established.Consequently,a systematic energy consumption prediction approach for die casting machines,involving product,die,equipment,and process parameters,is proposed.Finally,the feasibility and reliability of the proposed energy consumption prediction approach are verified with the help of three die casting machines and six types of products.The results show that the prediction accuracy of production time and energy consumption reached 91.64%and 85.55%,respectively.Overall,the proposed approach can be used for the energy consumption prediction of different die casting machines with different products.

关键词： die casting machine energy consumption prediction product parameters

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