ORCID Profile
0000-0002-9900-1112
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Publisher: Elsevier BV
Date: 2021
Publisher: Springer Science and Business Media LLC
Date: 16-05-2018
Publisher: IEEE
Date: 27-08-2021
Publisher: Springer Science and Business Media LLC
Date: 04-2020
Publisher: Springer Science and Business Media LLC
Date: 10-07-2017
Publisher: Institute of Electrical and Electronics Engineers (IEEE)
Date: 06-2019
Publisher: IEEE
Date: 12-07-2021
Publisher: Elsevier BV
Date: 11-2022
Publisher: ASME International
Date: 31-07-2018
DOI: 10.1115/1.4040872
Abstract: In five-axis milling process, the tool path generated by a commercial software seldom takes the dynamics of the machining process into account. The neglect of process dynamics may lead to milling chatter, which causes overcut, quick tool wear, etc., and thus damages workpiece surface and shortens tool life. This motivates us to consider dynamic constraints in the tool path generation. Tool orientation variations in five-axis ball-end milling influence chatter stability and surface location error (SLE) due to the varying tool-workpiece immersion area and cutting force, which inversely provides us a feasible and flexible way to suppress chatter and SLE. However, tool orientations adjustment for suppression of chatter and SLE may cause drastic changes of the tool orientations and affects surface quality. The challenge is to strike a balance between the smooth tool orientations and suppression of chatter and SLE. To overcome the challenge, this paper presents a minimax optimization approach for planning tool orientations. The optimization objective is to obtain smooth tool orientations, by minimizing the maximum variation of the rotational angles between adjacent cutter locations, with constraints of chatter-free and SLE threshold. A dedicated designed ball-end milling experiment is conducted to validate the proposed approach. The work provides new insight into the tool path generation for ball-end milling of sculpture surface also it would be helpful to decision-making for process parameters optimization in practical complex parts milling operations at shop floor.
Publisher: Elsevier BV
Date: 2019
Publisher: IEEE
Date: 29-06-2020
Publisher: ASME International
Date: 09-07-2018
DOI: 10.1115/1.4040618
Abstract: Milling chatters caused by the regenerative effect is one of the major limitations in increasing the machining efficiency and accuracy of milling operations. This paper studies robust active chatter control for milling processes with variable pitch cutters whose dynamics are governed by multidelay nonlinear differential equations. We propose a state feedback controller based on linear matrix inequality (LMI) approach that can enlarge multiple stability domains in the stability lobe diagram (SLD) while the controller gain is minimized. Numerical simulations of active magnetic bearing systems demonstrate the effectiveness of the proposed method.
Publisher: Springer Science and Business Media LLC
Date: 15-02-2020
Publisher: Elsevier BV
Date: 2017
Publisher: Springer International Publishing
Date: 2015
Publisher: ASME International
Date: 27-08-2020
DOI: 10.1115/1.4047623
Abstract: Chatter in low immersion milling behaves differently from that in full immersion milling, mainly because of the non-negligible time-variant dynamics and the occurrence of period doubling bifurcation. The intermittent and time-variant characteristics make the active chatter suppression based on Lyaponov theorem a non-trivial problem. The main challenges lie in how to deal with the time-variant directional coefficient and how to construct a suitable Lyaponov function so as to alleviate the conservation, as well as the saturation of the controller. Generally, the Lyaponov stability of time-invariant dynamics is more tractable. Hence, in our paper, a first-order piecewise model is proposed to approximate the low immersion milling system as two time-invariant sub-ones that are cyclically switched. To alleviate the conservation, a novel piecewise Lyaponov function is constructed to determine the stability of each subsystem independently. The inequality conditions for determining the stability and stabilization are derived. The validity of the proposed stabilization algorithm to suppress both the hopf and period doubling bifurcation, as well as to reduce the conservation of the controller parameters have been verified.
Publisher: Elsevier BV
Date: 11-2013
Publisher: Springer Science and Business Media LLC
Date: 21-11-2016
Publisher: IEEE
Date: 22-06-2021
Publisher: Institute of Electrical and Electronics Engineers (IEEE)
Date: 2023
Publisher: Springer Science and Business Media LLC
Date: 11-05-2021
Publisher: IEEE
Date: 12-2012
Publisher: Informa UK Limited
Date: 03-04-2021
Publisher: Elsevier BV
Date: 2018
Publisher: ASME International
Date: 03-08-2015
DOI: 10.1115/1.4030841
Abstract: In machining process, chatter is an unstable dynamic phenomenon which causes overcut and quick tool wear, etc. To avoid chatter, traditional methods aim to optimize machining parameters. But they have inherent disadvantage in gaining highly efficient machining. Active magnetic bearing (AMB) is a promising technology for machining on account of low wear and friction, low maintenance cost, and long operating life. The control currents applied to AMBs allow not only to stabilize the supported spindle but also to actively suppress chatter in milling process. This paper, for the first time, studies an integrated control scheme for stability of milling process with a spindle supported by AMBs. First, to eliminate the vibration of an unloaded spindle rotor during acceleration/deceleration, we present an optimal controller with proper compensation for speed variation. Next, the controller is further enhanced by adding an adaptive algorithm based on Fourier series analysis to actively suppress chatter in milling process. Finally, numerical simulations show that the stability lobe diagram (SLD) boundary can be significantly expanded. Also, a practical issue of constraints on controller output is discussed.
Publisher: Springer Science and Business Media LLC
Date: 27-04-2021
Publisher: ASME International
Date: 09-02-2018
DOI: 10.1115/1.4038947
Abstract: Machining process dynamics can be described by state-space delayed differential equations (DDEs). To numerically predict the process stability, erse piecewise polynomial interpolation is often utilized to discretize the continuous DDEs into a set of linear discrete equations. The accuracy of discrete approximation of the DDEs generally depends on how to deal with the piecewise polynomials. However, the improvement of the stability prediction accuracy cannot be always guaranteed by higher-order polynomials due to the Runge phenomenon. In this study, the piecewise polynomials with derivative-continuous at joint nodes are taken into consideration. We develop a recursive estimation of derived nodes for interpolation approximation of the state variables, so as to improve the discretization accuracy of the DDEs. Two different temporal discretization methods, i.e., second-order full-discretization and state-space temporal finite methods, are taken as demonstrations to illustrate the effectiveness of applying the proposed approach for accuracy improvement. Numerical simulations prove that the proposed approach brings a great improvement on the accuracy of the stability lobes, as well as the rate of convergence, compared to the previous recorded ones with the same order of interpolation polynomials.
Publisher: Elsevier BV
Date: 04-2015
Publisher: Institute of Electrical and Electronics Engineers (IEEE)
Date: 02-2021
Publisher: Institute of Electrical and Electronics Engineers (IEEE)
Date: 10-2018
Publisher: SPIE
Date: 11-05-2009
DOI: 10.1117/12.832076
Publisher: Springer Science and Business Media LLC
Date: 14-06-2013
Publisher: Wiley
Date: 11-12-2015
DOI: 10.1002/RNC.3493
Publisher: Elsevier BV
Date: 05-2015
Publisher: Elsevier BV
Date: 10-2015
Publisher: IEEE
Date: 12-2012
Publisher: SAGE Publications
Date: 15-07-2019
Abstract: Process d ing generated between the tool flank face and the wavy finish workpiece surface has a non-negligible effect on cutting dynamics and chatter stability, especially at low cutting speeds, resulting in higher stability limits. In modeling of process d ing, the calculation of extruded volume is one of the most critical challenges, especially in machining with honed tools due to the complex and time-variable contact condition between the arc cutting edge and the finite litude wave surface. In this study, a semi-analytical method with high computational efficiency is proposed to calculate the extruded volume in cutting with honed tools. Based on this method, we construct the stability lobes under the condition of finite vibration litude accurately and efficiently, which overcomes the limitation of analytical methods based on the assumption of small litude vibrations and the low computational efficiency of numerical method. The predicted cutting stability is verified against both the experimental results and the time-domain simulation results.
Publisher: IEEE
Date: 08-2019
No related grants have been discovered for Tao Huang.