译文英文完整.docx
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译文英文完整.docx
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译文英文完整
ENHANCEDDETERMINISTICDESIGN:
APPLICATIONTOAMICROCNCMACHINEDESIGN
ABSTRACT
Thispaperintroducesanenhanceddeterministicdesignb5E2RGbCAP
approachforthedesignofamicromechanicalsystemwithp1EanqFDPw
theobjectivetoachievebetteraccuracythrough
miniaturisation.ThemethodologyofdesignencompassesDXDiTa9E3d
optimisationusingTaguchitechnique,finiteelementRTCrpUDGiT
modelling,and,addedfunctionsconsideringanumberof5PCzVD7HxA
microphysicalproblemsthatmaycharacterisethemicrojLBHrnAILg
mechanicalsystem.TypicalmicrophysicalproblemsofaxHAQX74J0X
micromillingmachinewereenumeratedwithpossibilitiestoLDAYtRyKfE
includesomeofthemwithintheoverallmethodologywasZzz6ZB2Ltk
observed.MicrophysicaleffectsmaynotallhaveaknowndvzfvkwMI1
model.Anobjectivefunctionwascreatedtosatisfypartofrqyn14ZNXI
thespecifications.AnexampleofaverticalcolumnoftheEmxvxOtOco
micromillwasdesignedandevaluatedwithintheconceptofSixE2yXPq5
theproposeddesignmethodology.Initialresultsanderror6ewMyirQFL
assessmentmeasuredonthemicromachinearepresented.kavU42VRUs
Keyword:
Deterministicdesign,TaperedEggBridge,
verticalcolumn,designparameters,stiffness,deflection,y6v3ALoS89
naturalfrequency,Finiteelementmethod,Taguchimethod,M2ub6vSTnP
mathematicalmodel.
INTRODUCTION
Theactualproductionofmicro-partsisperformedby0YujCfmUCw
standardmachinetoolsconsuminghighenergy,occupyingeUts8ZQVRd
largespaceandrequiringlargeair-conditioned
environments。
thereforeitisimportanttosavedrivingsQsAEJkW5T
energy,spaceandresourcesincontrollingthesurroundingsGMsIasNXkA
(e.g.temperature,humidity>byapplyingtheconceptofTIrRGchYzg
micro-factoryandrobustdesignofmicro-machines.Various7EqZcWLZNX
approachestodesignmechanicalsystemsareestablishedandlzq7IGf02E
couldbesummarisedascreativeconceptfollowedbyzvpgeqJ1hk
deterministicmodelling[1,2],axiomaticdesign[3],robustNrpoJac3v1
designknownasTaguchimethod[4],customercentred1nowfTG4KI
product[5],and,systematicdesign[6,7].TheaspectsoffjnFLDa5Zo
virtualdesigncouldalsobeintroducedtoeasethedesigntfnNhnE6e5
processwithlessornoprototypestocheckforperformanceHbmVN777sL
andeconomicreasons.
Theexactmathematicalmodel
ThisisahighlyaccuratemathematicalrepresentationofV7l4jRB8Hs
theexpectedassemblyconfigurationofthemicromechanical83lcPA59W9
system/sub-systembeingdesigned.ThemodelwhichmaybemZkklkzaaP
basedonexistingmethodsofmodellingsuchsystem
configuration,shouldbeimprovedtoreflectthepresenceofAVktR43bpw
specificissuesthatcharacterisethemicromechanicalORjBnOwcEd
system.Effortshouldbemadetolumpmicrophysical2MiJTy0dTT
problemswhichrelatetothemicromechanicalsystemwithingIiSpiue7A
itsmodel.TheobjectiveofthedesignshouldalsofollowuEh0U1Yfmh
directlyfromthesespecificcharacteristicsofthemicroIAg9qLsgBX
mechanicalsystem.ThemathematicalmodelcouldthenbeWwghWvVhPE
executedinestablishedcommerciallyavailablesoftwarelikeasfpsfpi4k
MATLABforsimulatingthesystem.
TheCADmodel
Solid(CAD>modelofamicromechanicalsystem,e.g.aooeyYZTjj1
micromachinetoolcouldbedevelopedusingexistingBkeGuInkxI
softwaree.g.ProEngineerandAbaqus.Static,dynamicandPgdO0sRlMo
thermalanalysiscouldbeconductedonthesolidmodele.g.3cdXwckm15
Abaqus,andtheoutputcouldbeuseddirectlywithTaguchih8c52WOngM
methodorinconjunctionwiththecombinationofthev4bdyGious
mathematicalmodelandTaguchimethodtoconductrobustJ0bm4qMpJ9
analysisofthedesignconcept.However,important
componentsoftheCADmodelarethematerialandsectionXVauA9grYP
propertiesaswellastheloadingofandinteractionbetweenbR9C6TJscw
membersofthesolidmodelassembly.Wherenecessary,thepN9LBDdtrd
microphysicalproblemsrelatingtothesolidmodelassemblyDJ8T7nHuGT
shouldbeidentifiedandappropriatelyaddressedduringtheQF81D7bvUA
constructionofthemodel.Selectionofmodelparameterand4B7a9QFw9h
determinationofsimulationobjectiveshouldalsoconsiderix6iFA8xoX
themicroissuesthatspecifythesystem,sothatthewt6qbkCyDE
simulationrepresentscloselytheactualsystemunderKp5zH46zRk
consideration.TheoutputintermsofdimensionsisreturnedYl4HdOAA61
toFEMforfinalanalysis.
Fig.1:
Generaldesignsteps
Thetechnologygapbetweenmicroandmacro/standardch4PJx4BlI
mechanicalsystemdesigncouldbeassociatedwithsteps3qd3YfhxCzo
and4.BytakingcareoftheissuesspecifictomicroE836L11DO5
mechanicalsystemswithinitsdesignmethodatthesaidS42ehLvE3M
stepshighqualityproductandaccuracycouldbeachieved.501nNvZFis
ThedesignmethodologywillencompassafewcriticalstepsjW1viftGw9
suchasthechoiceofdesignconcepts/parametersthatmayxS0DOYWHLP
securehighersystemquality.TheinclusionofcriticalsystemLOZMkIqI0w
conditionstotheappropriatestepsinthedesignmethodisZKZUQsUJed
highlyimportanttoconvergetowardsamore‘exact’system.dGY2mcoKtT
ThesequenceDesign-Analysis-PerformancecouldthenberCYbSWRLIA
usedasacontinuousiterationwithrespecttothe
performancequality.ThecensusofthefactorsthatmayFyXjoFlMWh
affecttheperformanceisnecessaryforaneventualTuWrUpPObX
minimisationoferrorandenhancementofaccuracyofthe7qWAq9jPqE
micromechanicalsystem.ItisimportanttoassessthellVIWTNQFk
physicalphenomenaatsmallscaleandchecktheireffectyhUQsDgRT1
overthemachineperformance[10].Basedonthis
backgroundthisstudyhasproposedanenhanced
deterministicdesignmethodforthedesignofmicroMdUZYnKS8I
mechanicalsystems.
Thepurposeofthispaperisanattempttobuildupa09T7t6eTno
designprocedureformicromachinesforwhichitisbelievede5TfZQIUB5
thatstandardproceduresarenotsufficient.Themethods1SovAcVQM
includessomeoptimisationcomputationandshapefunctionsGXRw1kFW5s
combinedwiththedeterministicmethodinonestreamline.UTREx49Xj9
Fig.2:
Theenhanceddeterministicdesignmethod.
Thoughthecomponentsofthemethodologyarewell
knowntothedesigncommunity,theyarecombinedina8PQN3NDYyP
uniquewaywithspecialconsiderationofthespecificmLPVzx7ZNw
characteristicsofthemicromechanicalsystemtoreflecttheAHP35hB02d
essentialmicrophysicalphenomenaofthesystem.TheNDOcB141gT
proposedmethodwouldbeusefulinthedesignofdifferent1zOk7Ly2vA
typesofmicromachinetoolconfigurationsandits
subsystems,therebyenablinga'rightdesign'thefirsttimeoffuNsDv23Kh
themachinetool.ThemicrophysicalproblemsassociatedtotqMB9ew4YX
themicromechanicalsystemwouldbelumpedwithintheHmMJFY05dE
mathematicalmodelwhichoftenrepresentsthecombinationViLRaIt6sk
and/orrelationshipsbetweenmembersofthemicro
mechanicalsystemintermsofitsquality.Fortheindividual9eK0GsX7H1
membersofthesystemthecomponentsoftheproposednaK8ccr8VI
designapproachbeingutilisedmaybelimitedtotheCADB6JgIVV9ao
modelandTaguchimethod.Inthiscase,itmaybedifficultP2IpeFpap5
torepresentthemicrophysicalphenomenawithinthe3YIxKpScDM
strategybuttheyobviouslyindicateorfacilitatethegUHFg9mdSs
understandingoftheobjectivefunctionsofthedesignbeinguQHOMTQe79
considered.
Fig.3:
Lumpedparametermodelofthemicromill.
a>Accuracyofthedimensionsofmachinetool
elements/components.Asthemachineelementsare
producedmainlybymechanicalmachining,machiningerrorIMGWiDkflP
upto1μm(andmore>mayappearinthedimensionsoftheWHF4OmOgAw
micromachineelements.ThiscouldbeclassifiedasaDFdk6hhPd
assemblyerroranditwouldaffecttheoverallaccuracyoftheozElQQLi4T
machinetoolwhensuchcomponentsareassembled.
b>Thestandardboltpreloadrequiredforjoining
componentsormembersofamicromachinetooltogetherCvDtmAfjiA
wouldlikelydistortthemembersofthemachinesincetheyQrDCRkJkxh
areaveragelyslender.Althoughthedeformation(also4nCKn3dlMX
classifiedasassemblyerror>maynotbeveryhighbutitijCSTNGm0E
wouldhavehighimpactonthemachinetoolaccuracysincevfB1pxanfk
sub-micronsmachiningofconcern.
c>Thecuttingforceand/oranyslightriseintemperatureJbA9VhEou1
couldeasilypropagatethroughanddeformtheassembledX7Ahr18pJI
componentsofamicromachine.Astinytoolandsmallpartb3zqXLCqXo
tobemachinedareeasilydeformed,thethermalandcuttingpZyytu5rc5
forceinduceddeformationisworthyofconsideration.DVyGZezsrM
d>TherelativemotionerrorbetweenadjacentmembersRQxPvY3tFs
ofamicromachinetoolduetotheallowedgapbetweenthe5MxX1IxuU9
boltandtheholethataccommodatetheboltisnotnegligible.jIw5xs0v9P
e>Theextrarun-outaddedtothespindlerun-outcausedxEve2buwnw
bytheassemblyofthemicrocuttingtoolandthespindleKAvmyVYxCd
throughthecollet.Usually,therun-outismuchsmallerthanYwuu4FszRT
thetooldiameterhenceneglected,butinthecaseofcstDApWA6A
micromachining,therun-outcannotbeignored[16]duetheqotL69pBkh
sizeaspectratiosandhighspeedspindle.
f>VeryhighspindlespeedrequiredforatinytoolinEksTCSTCzX
ordertorealizebothanefficientcuttingspeedandaSgs28CnDOE
productivemetalremovalrate.Thiswouldresultinhigh6craEmRE2k
excitationfrequencyontheassembledmachinetool
components.Considerasimplelumpedparametermodelofk8qia6lFh1
themicromillwhichcouldrepresentitsdynamicbehavioury3qrGQOGwI
alongthecuttingdirection(Fig.3>.
g>ForagivencuttingforceF,thespindle-collet
assemblyaswellasthetoolwouldhavetorunatveryhighMZpzcAiHKo
speedforhighefficiency.But,theboltedjointsinFig.3are0VoHIjMIZ5
weakinmicromachines[17].
Thismeansthat
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