Grinding of aluminium silicon carbide metal matrix composite materials by electrolytic in-process dressing grinding

Shanawaz, A.M.; Sundaram, S.; Pillai, U.T.S.; Aurtherson, P. Babu

doi:10.1007/s00170-011-3288-4

Cited by 28 publications

(12 citation statements)

References 10 publications

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“…In the static state and without additional load, the gravity G of the end effector is expressed in the world coordinate frame as: (4) Assumptions:…”

Section: Six-dimensional Force Sensor Gravity Compensation and Zero Drift Compensationmentioning

confidence: 99%

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Research on Constant Force Polishing Control of Aero-engine Blade Based on Expanded State Observer

Zhang¹,

Dai²,

Zhao³

et al. 2021

Preprint

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This paper presents a parallel control method based on the expanded state observer (ESO) for aero-engine blade robot polishing. Aiming to reduce the fluctuation of polishing force caused by environmental noise and modeling errors. First, calibrate six-dimensional force sensor according to the maximum acceleration of the end effector during the polishing process. Then, build the gravity compensation and zero drift compensation model. Besides, use this model to compensate measurement error of the six-dimensional force sensor. Finally, calculate the error between the expected polishing force and the actual feedback value and its derivative value. Use calculation results to design the control boundary layer. The polishing force controller is divided into two parallel control loops to design. When the switching value is in the control boundary layer. A nonlinear active disturbance rejection control (ADRC) loop is used. When the switching value is outside the control boundary layer. An ESO-based sliding mode control (SMC) loop is used. Simulation and experimental results show that the proposed parallel control method based on ESO has a fast response and high robustness compared with FuzzyPID, PID, and ADRC. It can effectively suppress the force fluctuation in the polishing process and significantly improve the surface processing quality of the aero-engine blade.

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“…In the static state and without additional load, the gravity G of the end effector is expressed in the world coordinate frame as: (4) Assumptions:…”

Section: Six-dimensional Force Sensor Gravity Compensation and Zero Drift Compensationmentioning

confidence: 99%

“…For example, electrolytic polishing has been used on hard and brittle materials. It can effectively improve the material removal rate and reduce the polishing wheel rate of wear [4][5]. But those techniques are mainly used for rough machining [6].…”

Section: Introductionmentioning

confidence: 99%

Research on Constant Force Polishing Control of Aero-engine Blade Based on Expanded State Observer

Zhang¹,

Dai²,

Zhao³

et al. 2021

Preprint

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show abstract

“…The electrolytic in-process dressing (ELID) technique applies an electric current during the conventional grinding process. Shanawaz et al [330] employed ELID for the machining of low fraction SiC p /Al composites and found that a smoother surface could be obtained at a high current duty ratio. Yu et al [331] obtained a high-integrity machined surface for a high-SiC fraction (56%(volume fraction)) SiC p /Al composite.…”

Section: Other Hybrid Machining Technologiesmentioning

confidence: 99%

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Chen

2020

Adv. Manuf.

103

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Among the various types of metal matrix composites, SiC particle-reinforced aluminum matrix composites (SiC p /Al) are finding increasing applications in many industrial fields such as aerospace, automotive, and electronics. However, SiC p /Al composites are considered as difficult-to-cut materials due to the hard ceramic reinforcement, which causes severe machinability degradation by increasing cutting tool wear, cutting force, etc. To improve the machinability of SiC p /Al composites, many techniques including conventional and nonconventional machining processes have been employed. The purpose of this study is to evaluate the machining performance of SiC p /Al composites using conventional machining, i.e., turning, milling, drilling, and grinding, and using nonconventional machining, namely electrical discharge machining (EDM), powder mixed EDM, wire EDM, electrochemical machining, and newly developed high-efficiency machining technologies, e.g., blasting erosion arc machining. This research not only presents an overview of the machining aspects of SiC p /Al composites using various processing technologies but also establishes optimization parameters as reference of industry applications.

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“…Mao C et al [1] found that the grinding depth affected the grinding force of CBN-WC-10Co mostly: the pull-out and brittle fractures of CBN particle were the main reasons for the increase of surface roughness. Shanawaz A et al [2] studied the ELID grinding of the low-volume fraction SiCp/Al composite; they found that the grinding force was smaller and more stable than the traditional grinding process and observed that higher electric currents produced a better surface quality. Huang S et al [3] studied the grinding force of SiCp/Al composite in four different types of grinding environment: they noticed that the grinding force was the largest in low-temperature environments and the smallest in wet environments.…”

Section: Introductionmentioning

confidence: 99%

Grinding temperature prediction model of high-volume fraction SiCp/Al composite

Zhu

Ping

et al. 2020

Int J Adv Manuf Technol

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Grinding is the main processing technique for particle-reinforced composites, in which grinding force and temperature are significant for investigating the removal mechanism and surface properties. In this study, a grinding force prediction model is established based on the response surface methodology. The energy density of surface heat source in the grinding area is calculated by combining the contact area between the grinding wheel and workpiece. Based on the integration algorithm in time and space, a theoretical ideal grinding temperature prediction model is deduced. The grinding heat energy transfer coefficient is defined as the percentage of heat energy, which is transferred from the grinding heat energy to the workpiece. According to the experimental and ideal theoretical highest grinding temperatures, a prediction model of the heat energy transfer coefficient is established, and the modified theoretical highest grinding temperature prediction model is obtained. Furthermore, a finite element model of SiCp/Al composite in grinding is established. The highest grinding temperature in the finite element model is consistent with the modified theoretical highest grinding temperature, and the grinding temperature field is analysed. The highest grinding temperature increases as the wheel speed and grinding depth increase, while it decreases as table speed increases, which differs from that of some common materials. Thus, the grinding temperature prediction model provides an important reference for the study of removal mechanism and surface properties of SiCp/Al composite.

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Grinding of aluminium silicon carbide metal matrix composite materials by electrolytic in-process dressing grinding

Cited by 28 publications

References 10 publications

Research on Constant Force Polishing Control of Aero-engine Blade Based on Expanded State Observer

Research on Constant Force Polishing Control of Aero-engine Blade Based on Expanded State Observer

A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites

Grinding temperature prediction model of high-volume fraction SiCp/Al composite

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