Zhaojun Gu

Bio: Zhaojun Gu is an academic researcher from Civil Aviation University of China. The author has contributed to research in topics: Machining & Surface roughness. The author has an hindex of 1, co-authored 5 publications receiving 3 citations.

Transient separation cutting characteristic of axial ultrasonic vibration–assisted cutting

Abstract: Axial ultrasonic vibration–assisted cutting has been proposed and proved preponderance on cutting performance; however, the transient separation cutting characteristic has not been clearly revealed. This paper focuses on the transient separation cutting characteristic of axial ultrasonic vibration–assisted cutting and its influence on the cutting performance. First, the separation cutting criteria, including feed coefficient and phase shift, are established and influence factors, such as feed rate, amplitude, and phase shift, are systematically analyzed. Subsequently, the duty ratio is deduced and calculated, and some features and a control mechanism are introduced. In addition, a transient separation cutting model with four stages is demonstrated. The reason for the average cutting force reduction by the transient separation cutting characteristic is also stated. Finally, the verification of the separation cutting and transient separation cutting model and the comparison of the feed thrust force and parameter influences on the cutting performance are experimentally performed. The transient signals of different duty ratios 0.55 to 1 are obtained, and 10 to 40% reductions of feed thrust are measured both by a PCB sensor and a Kistler dynamometer. The influence degree of the feed coefficient, spindle rotation speed, and cutting depth on the performance is analyzed. A parameter combination of smaller feed coefficient, moderate spindle rotation speed, and smaller cutting depth is suggested to obtain a better cutting performance by fully considering the cutting force, surface roughness, and tool life.

Cybersecurity risk assessment method of ICS based on attack-defense tree model

Abstract: Cybersecurity risk assessment is an important means of effective response to network attacks on industrial control systems. However, cybersecurity risk assessment process is susceptible to subjective and objective effects. To solve this problem, this paper introduced cybersecurity risk assessment method based on fuzzy theory of Attack-Defense Tree model and probability cybersecurity risk assessment technology, and applied it to airport automatic fuel supply control system. Firstly, an Attack-Defense Tree model was established based on the potential cybersecurity threat of the system and deployed security equipment. Secondly, the interval probability of the attack path was calculated using the triangular fuzzy quantification of the interval probabilities of the attack leaf nodes and defensive leaf nodes. Next, the interval probability of the final path was defuzzified. Finally, the occurrence probability of each final attack path was obtained and a reference for the deployment of security equipment was provided. The main contributions of this paper are as follows: (1) considering the distribution of equipment in industrial control system, a new cybersecurity risk evaluation model of industrial control system is proposed. (2) The experimental results of this article are compared with other assessment technologies, and the trend is similar to that of other evaluation methods, which proves that the method was introduced in this paper is scientific. However, this method reduces the subjective impact of experts on cybersecurity risk assessment, and the assessment results are more objective and reasonable. (3) Applying this model to the airport oil supply automatic control system can comprehensively evaluate risk, solve the practical problems faced by the airport, and also provide an important basis for the cybersecurity protection scheme of the energy industry.

Feasibility study on machining extra-large aspect ratio aviation deep-hole Ti6Al4V part with axial ultrasonic vibration-assisted boring

Abstract: Deep-holes are typical parts of aircraft structures, which is difficult to be machined. Boring assisted with ultrasonic vibration-assisted cutting has been proved to greatly enhance machining performance, especially for Ti6Al4V aviation alloy. This paper focuses on the machining extra-large aspect ratio (exceeding 20) of Ti6Al4V aviation deep-hole with the axial ultrasonic vibration-assisted boring (AUVB) method. First, the kinetics of the AUVB process is analyzed and a retrospective of its separation cutting feature is provided. Subsequently, a multi-stepped cantilever beam model of boring bar is established to analyze its static rigidity and dynamic stability. The aperture error is deduced, and then size coefficient is put forward to represent the static rigidity of the boring bar, which is inversely proportional to the diameter. In addition, two different vibration cases, namely modal-coupling vibration and regenerative vibration are considered for dynamic stability analysis. Next, the morphology of bored surface is analyzed, and the geometric height of peaks formed by AUVB and CB are calculated. Phase shift φ= π is suggested for obtaining a better surface in AUVB. Finally, the feasibility of AUVB on the machining of extra-large aspect ratio Ti6Al4V titanium alloy aviation deep-hole is verified through systematic experiments. Results demonstrate that AUVB has obvious advantages in reducing boring force, improving boring accuracy, suppressing vibration and promoting surface quality. Furthermore, the aperture error decreases to 50% and vibration amplitudes decrease to only 20–25%. The overall surface roughness of the deep-hole part stays below Ra=0.8μm with rotational speeds of 60r/min and 80r/min, and the surface residual stress state is transferred from the tensile state to a compressive one. As a result, not only AUVB can provide better boring accuracy and surface finish, but it also can enhance the surface fatigue properties.

Theoretical and experimental investigation into the machining performance in axial ultrasonic vibration-assisted cutting of Ti6Al4V

Abstract: Axial ultrasonic vibration-assisted cutting (AUVC) has been proved to have better machining performance compared with conventional cutting methods; however, the effect of numerous and complex influencing factors on machining performance has not been clearly revealed, and a recommended combination of cutting conditions has not been proposed yet, especially for difficult-to-machine material such as Ti6Al4V alloy. This paper focuses on the experimental and theoretical investigation into Ti6Al4V machining performance with AUVC method. First, a retrospective of the separation characteristics of AUVC is provided, and the variable parameter cutting characteristics are demonstrated. The influencing factors on machining performance are classified into four categories: machining parameters, vibration parameters, tool choice, and cooling conditions. The relationship between these factors in terms of their effect on machining performance is established theoretically. Then, it describes experiments to determine the influence of these factors on cutting force, tool life, and surface roughness. For absolute influence, the orders for cutting force, tool life, and surface roughness are respectively cutting depth > amplitude > feed rate > rotation speed, rotation speed > feed rate > amplitude > cutting depth, and feed rate > amplitude > cutting depth > rotation speed. However, for relative influence, the order is unified as amplitude > feed rate > rotation speed > cutting depth. Finally, it suggests a smaller feed rate, larger amplitude, moderate rotation speed, and smaller cutting depth in addition to a WC tool coated with TiAlN and used under HPC cooling condition for optimal performance of AUVC. This recommendation is based on the theoretical analysis and experimental results of cutting force, surface roughness, and tool life.

Simulation and experimental research on extra-squeeze forming method during gradient sand molding

Abstract: The flexible extrusion forming process (FEFP) is a sand mold patternless manufacturing technology that enables digital near-net shaping of complex sand molds. But, it is difficult to achieve the gradient sand molds with high surface strength and strong interior permeability by FEFP. To solve this problem, an extra-squeeze forming method based on FEFP for gradient sand mold was developed. To further reveal the extra-squeeze forming mechanism, based on the Johnson-Kendall-Roberts (JKR) theory and “gluing” notions, the single and double-sided squeeze models of gradient sand molds were established using the EDEM software. The squeezing processes of sand molds with different cavity depths of 60, 100, 140, 180, and 220 mm were systemically studied under single and double-sided squeeze conditions. The variation in the void fraction of sand mold as also investigated at a variety of extra-squeeze distances of 2, 3, 4, 5, and 6 mm, respectively. Simulation and test results show that a deeper cavity depth weakens the extrusion force transmission, which leads to a decrease in strength. The sand mold permeability and void fraction are identified to be positively correlated, while the tensile strength and void fraction appear to be negatively correlated. The void fraction of sand molds decreases with a longer extra-squeeze distance. A 6 mm extra-squeeze distance for the sand mold with 220 mm cavity depth results in a 26.8% increase in tensile strength with only a 5.7% reduction in the permeability. Hence, the extra-squeeze forming method can improve the quality of the sand mold by producing a gradient sand mold with high surface strength and strong interior permeability.

Feasibility study on machining extra-large aspect ratio aviation deep-hole Ti6Al4V part with axial ultrasonic vibration-assisted boring

Abstract: Deep-holes are typical parts of aircraft structures, which is difficult to be machined. Boring assisted with ultrasonic vibration-assisted cutting has been proved to greatly enhance machining performance, especially for Ti6Al4V aviation alloy. This paper focuses on the machining extra-large aspect ratio (exceeding 20) of Ti6Al4V aviation deep-hole with the axial ultrasonic vibration-assisted boring (AUVB) method. First, the kinetics of the AUVB process is analyzed and a retrospective of its separation cutting feature is provided. Subsequently, a multi-stepped cantilever beam model of boring bar is established to analyze its static rigidity and dynamic stability. The aperture error is deduced, and then size coefficient is put forward to represent the static rigidity of the boring bar, which is inversely proportional to the diameter. In addition, two different vibration cases, namely modal-coupling vibration and regenerative vibration are considered for dynamic stability analysis. Next, the morphology of bored surface is analyzed, and the geometric height of peaks formed by AUVB and CB are calculated. Phase shift φ= π is suggested for obtaining a better surface in AUVB. Finally, the feasibility of AUVB on the machining of extra-large aspect ratio Ti6Al4V titanium alloy aviation deep-hole is verified through systematic experiments. Results demonstrate that AUVB has obvious advantages in reducing boring force, improving boring accuracy, suppressing vibration and promoting surface quality. Furthermore, the aperture error decreases to 50% and vibration amplitudes decrease to only 20–25%. The overall surface roughness of the deep-hole part stays below Ra=0.8μm with rotational speeds of 60r/min and 80r/min, and the surface residual stress state is transferred from the tensile state to a compressive one. As a result, not only AUVB can provide better boring accuracy and surface finish, but it also can enhance the surface fatigue properties.

Theoretical and experimental investigation into the machining performance in axial ultrasonic vibration-assisted cutting of Ti6Al4V

Abstract: Axial ultrasonic vibration-assisted cutting (AUVC) has been proved to have better machining performance compared with conventional cutting methods; however, the effect of numerous and complex influencing factors on machining performance has not been clearly revealed, and a recommended combination of cutting conditions has not been proposed yet, especially for difficult-to-machine material such as Ti6Al4V alloy. This paper focuses on the experimental and theoretical investigation into Ti6Al4V machining performance with AUVC method. First, a retrospective of the separation characteristics of AUVC is provided, and the variable parameter cutting characteristics are demonstrated. The influencing factors on machining performance are classified into four categories: machining parameters, vibration parameters, tool choice, and cooling conditions. The relationship between these factors in terms of their effect on machining performance is established theoretically. Then, it describes experiments to determine the influence of these factors on cutting force, tool life, and surface roughness. For absolute influence, the orders for cutting force, tool life, and surface roughness are respectively cutting depth > amplitude > feed rate > rotation speed, rotation speed > feed rate > amplitude > cutting depth, and feed rate > amplitude > cutting depth > rotation speed. However, for relative influence, the order is unified as amplitude > feed rate > rotation speed > cutting depth. Finally, it suggests a smaller feed rate, larger amplitude, moderate rotation speed, and smaller cutting depth in addition to a WC tool coated with TiAlN and used under HPC cooling condition for optimal performance of AUVC. This recommendation is based on the theoretical analysis and experimental results of cutting force, surface roughness, and tool life.

An improved normal sawing force model with spherical abrasive particles for ultrasonic assisted inner diameter sawing

Abstract: Abstract Ultrasonic assisted inner diameter machining is a common slicing method for hard and brittle materials, and the sawing force is the main factor affecting the quality of workpiece surface and tool life, so to explore the sawing force is to research the sawing process. An improved model of normal sawing force is proposed in this paper with spherical abrasive particles. A series of sawing experiments were carried out with alumina ceramics (99%) as typical hard and brittle materials to verify the correctness of the theoretical model and discuss the influence of machining parameters on the normal sawing force. In the experiment, the results show that the average error and the variance of the improved normal sawing force model are decreased obviously compared with the average error and the variance of the regular tetrahedral abrasive normal sawing force model. So, the model proposed in this paper is more accurate. The establishment of this model has guiding significance for the selection of process parameters, the improvement of processing efficiency and quality in subsequent actual production and processing.

Cybersecurity Risk Assessment of Industrial Control Systems Based on Order-α Divergence Measures Under an Interval-Valued Intuitionistic Fuzzy Environment

Abstract: With the increasing deployment of network technologies in industrial control systems (ICSs), cybersecurity has become a challenge in ICSs. Cybersecurity risk assessment (CRA) plays an important role in cybersecurity protection of ICSs. However, the weights of risk indices are constants in traditional CRA methods, and they do not fully consider the requirements of risk identification. In this paper, we define a novel order- $\alpha $ divergence measure for interval-valued intuitionistic fuzzy numbers (IVIFNs) and further develop a novel CRA approach for ICSs based on the proposed divergence measure under an interval-valued intuitionistic fuzzy environment to contribute to the research gap. First, an order- $\alpha $ divergence measure for IVIFNs is defined considering flexibility and robustness of divergence measures with the parameter. Next, a variable weight-based CRA approach for ICSs is developed. In this approach, IVIFNs are adopted to describe evaluation values of risk indices. The weights of risk indices are variable weight vectors and they are determined by the relative divergence closeness. Integration approaches of each node and each attack path in attack-defense trees (ADTs) are proposed based on the operations of IVIFNs, and risk scores of each attack path are calculated by using the score function. Finally, we apply the proposed method to the CRA of a civil aviation fuel supply automatic control system and verify its effectiveness and advantages by comparing it with other methods. This method can dynamically adjust the weights of risk indices considering the relationship between each risk index and the highest risk, and therefore, it can more effectively recognize the highest risk of ICSs than the traditional CRA method. In addition, it can also match the risk attitude of decision-makers by adjusting the parameter $\alpha $ .