Feihu Zhang

Measurement and analysis for frequency domain error of ultra-precision spindle in a flycutting machine tool:

The ultra-precision spindle is the key component of ultra-precision machine tool, which largely influences the machining accuracy. Its frequency characteristics mainly affect the frequency domain error of the machined surface. In this article, the error measurement setup for the ultra-precision aerostatic spindle in a flycutting machine tool is established. The dynamic and multi-direction errors of the spindle are real-time measured under different rotation speeds. Then, frequency domain analysis is carried out to obtain its regularity characteristics based on the measurement result. Through the analysis, the main synchronous and asynchronous errors with relatively large amplitude of the spindle errors are found, and the amplitude change law of these main spindle errors is obtained. Besides, the cause of the main synchronous and asynchronous errors is also analyzed and indicated. This study deepens the understanding of ultra-precision spindle dynamic characteristics and plays the important role in the spindle frequency domain errors’ control, machining process planning, frequency characteristics analysis and oriented control of the machined surface errors.

Relationship between Asperity-Mediated Surface Forces and Topography Alteration of Silica Microspheres Sliding on Mica, Sapphire, and Glass Substrates under Ambient Conditions: Atomic Force Microscopy and Theoretical Studies

Contact geometry significantly influences adhesive force measurements and modeling for adhesion/friction studies where an AFM colloidal probe technique has been extensively employed. Here we present a systematic study on the topography alteration of silica microspheres sliding on mica, sapphire, and glass substrates under ambient conditions at a relative humidity of 30-55% and the consequential adhesion behaviors of worn microspheres through AFM direct force measurements and theoretical modeling. The wearing of microspheres creates a truncated platform, which is largest for sliding on glass substrates. On the platform are nanoasperities consisting of wear debris and airborne particulate contaminants. Variations in adhesive forces with sliding time and testing modes as well as the effect of surface roughness of substrates are explained within the theoretical framework of nanoasperity-mediated capillary and van der Waals forces. The drawbacks of the present reverse-imaging method for microsphere topography examination, and numerous sources of errors associated with the extraction of key parameters for force modeling, are discussed in detail. The results will also have important implications for more reliable AFM colloidal probe technique and its application in adhesion and tribological studies.

A two-round design method for ultra-precision flycutting machine tools with stringent process requirements

In order to achieve the special functional surfaces machining, a two-round design method for the ultra-precision machine tool design is proposed in this article. This method starts from the engineering design experience; by alternately using the simulation and experiment, the “design-simulation-experiment-simulation-redesign experiment” strategy is employed to the machine tool design. The main influence factors for all of the specifications are determined by this alternating strategy. The analysis of the machine tool performance and the surface generation simulation are well integrated, and the test software is used early at the design stage to estimate the predicted surface. This design method is used for an ultra-precision flycutting machine tool design for potassium dihydrogen phosphate crystal machining, and the results show that by the two rounds of design and modification, the final machine tool meets the processing requirements well. It is believed that the proposed model can be successfully applied to an ultra-precision machine tool designed for achieving strict processing requirements.

Thermal Influence of the Couette Flow in a Hydrostatic Spindle on the Machining Precision

Hydrostatic spindles are increasingly used in precision machine tools. Thermal error is the key factor affecting the machining accuracy of the spindle, and research has focused on spindle thermal errors through examination of the influence of the temperature distribution, thermal deformation and spindle mode. However, seldom has any research investigated the thermal effects of the associated Couette flow. To study the heat transfer mechanism in spindle systems, the criterion of the heat transfer direction according to the temperature distribution of the Couette flow at different temperatures is deduced. The method is able to deal accurately with the significant phenomena occurring at every place where thermal energy flowed in such a spindle system. The variation of the motion error induced by thermal effects on a machine work-table during machining is predicated by establishing the thermo-mechanical error model of the hydrostatic spindle for a high precision machine tool. The flow state and thermal behavior of a hydrostatic spindle is analyzed with the evaluated heat power and the coefficients of the convective heat transfer over outer surface of the spindle are calculated, and the thermal influence on the oil film stiffness is evaluated. Thermal drift of the spindle nose is measured with an inductance micrometer, the thermal deformation data 1.35 μm after running for 4 h is consistent with the value predicted by the finite element analysis’s simulated result 1.28 μm, and this demonstrates that the simulation method is feasible. The thermal effects on the processing accuracy from the flow characteristics of the fluid inside the spindle are analyzed for the first time.

Carriage Error Identification Based on Cross-Correlation Analysis and Wavelet Transformation

This paper proposes a novel method for identifying carriage errors. A general mathematical model of a guideway system is developed, based on the multi-body system method. Based on the proposed model, most error sources in the guideway system can be measured. The flatness of a workpiece measured by the PGI1240 profilometer is represented by a wavelet. Cross-correlation analysis performed to identify the error source of the carriage. The error model is developed based on experimental results on the low frequency components of the signals. With the use of wavelets, the identification precision of test signals is very high.

High-Contrast SEM Imaging of Supported Few-Layer Graphene for Differentiating Distinct Layers and Resolving Fine Features: There is Plenty of Room at the Bottom

For supported graphene, reliable differentiation and clear visualization of distinct graphene layers and fine features such as wrinkles are essential for revealing the structure-property relationships for graphene and graphene-based devices. Scanning electron microscopy (SEM) has been frequently used for this purpose where high-quality image contrast is critical. However, it is surprising that the effect of key imaging parameters on the image contrast has been seriously undermined by the graphene community. Here, superior image contrast of secondary electron (SE) images for few-layer graphene supported on SiC and SiO2 /Si is realized through simultaneously tuning two key parameters-acceleration voltage (Vacc ) and working distance (WD). The overlooked role of WD in characterizing graphene is highlighted and clearly demonstrated. A unified model of Vacc and WD dependence of three types of SE collected by the standard side-attached Everhart-Thornley (E-T) SE detector is conceptually developed for mechanistically understanding the improved mass thickness contrast for supported few-layer graphene. The findings reported here will have important implications for effective characterizations of atomically thick 2D materials and devices.

Study on grinding surface deformation and subsurface damage mechanism of reaction-bonded SiC ceramics:

In order to explore the grinding surface deformation and subsurface damage mechanism for reaction-bonded SiC ceramics, the grinding experiment for reaction-bonded SiC ceramics was carried out under the condition of different grinding depths using two different kinds of grain sizes of grinding wheel. The ground surface morphology of specimen was observed using the field emission scanning electron microscope (5000 ×), and the value of surface roughness Rz was measured by the confocal microscope, which found that there were the brittle removal region and the plastic removal region on the ground surface of reaction-bonded SiC ceramics and it could improve the ground surface quality and proportion of ductile region using the fine grinding wheel and reducing the grinding depth. The specimen was polished by the ion cross section polisher and the ground subsurface was analyzed by the field emission scanning electron microscope, which found that there were transgranular fracture, intergranular fracture, crack bifurcation, ladder-shaped crack and other phenomenon in the grinding process. And it could control the subsurface damage depth using the fine grinding wheel and reducing the grinding depth. The relationship between surface roughness and subsurface damage was analyzed based on the indentation theory, which found that the simulation results were close to the experiment results when the value of m is in the range of 1/8–1/4. When m is 0.2143 calculated by genetic algorithm, the simulation results are the best.

A new grinding force model for micro grinding RB-SiC ceramics with grinding wheel topography as an input

The ability to predict the grinding force for hard and brittle materials is important to optimize and control the grinding process. However, it is a difficult task to establish a comprehensive grinding force model that takes into account the brittle fracture, grinding conditions, and random distribution of the grinding wheel topography. Therefore, this study developed a new grinding force model for micro-grinding of reaction-bonded silicon carbide (RB-SiC) ceramics. First, the grinding force components and grinding trajectory were analysed based on the critical depth of rubbing, ploughing, and brittle fracture. Afterwards, the corresponding individual grain force were established and the total grinding force was derived through incorporating the single grain force with dynamic cutting grains. Finally, a series of calibration and validation experiments were conducted to obtain the empirical coefficient and verify the accuracy of the model. It was found that ploughing and fracture were the dominate removal modes, which illustrate that the force components decomposed are correct. Furthermore, the values predicted according to the proposed model are consistent with the experimental data, with the average deviation of 6.793% and 8.926% for the normal and tangential force, respectively. This suggests that the proposed model is acceptable and can be used to simulate the grinding force for RB-SiC ceramics in practice.

Forecasting Model for the Machining Accuracy of Aspheric Surface

Forecasting the accuracy of a machined surface shape is of a great concern for ultra-precision machining. Quick and accurate selection of the machining parameters and prediction of the measuring accuracy of the machined surface may reduce the time of experiment, shorten the cycle of machining and lower down production costs. This paper studied the parabolic aspheric surface, analyzed the main machining factors that affect the aspheric accuracy and established its back-propagation (BP) Neural Network (NN) model with experimental data taken into account. The model was used to predict the machining accuracy of the aspheric surface which is affected by various factors. Its prediction proves that the method is highly accurate.