共查询到20条相似文献,搜索用时 46 毫秒
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由于大量高硬度增强相SiC颗粒的存在,高体积分数铝基碳化硅(SiCp/Al)复合材料的机械加工十分困难。旋转超声加工被认为是加工这种材料的有效方法。通过超声辅助划痕试验,分析高体积分数SiCp/Al复合材料旋转超声铣磨加工的材料去除机理。在超声振动的作用下,材料中铝基体发生塑性变形,其表面得到夯实;SiC增强相被锤击成细小的颗粒而发生脱落,形成较大的空洞。由于材料加工的缺陷大多产生于SiC颗粒的去除过程中,SiC颗粒的去除方式对加工表面的质量起着决定性的作用,选择合适的工艺参数可以有效提高加工表面质量。旋转超声加工工艺特征试验表明,超声振动可有效降低切削力;主轴转速对轴向切削力的影响最大,其次是进给速度,切削深度对轴向切削力的影响较小;另外主轴转速对表面质量的影响效果也最大,并随主轴转速的增大表面粗糙度增大。因此在加工过程中,可以适当加大切削深度,在保证加工质量的基础上,选择较大的进给速度,在保证刀具寿命的前提下,选择合适的主轴转速,以获得较优的加工表面质量和加工效率。 相似文献
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Effect of turning parameters on surface roughness of A356/5% SiC composite produced by electromagnetic stir casting 总被引:1,自引:0,他引:1
S. P. Dwivedi Sudhir Kumar Ajay Kumar 《Journal of Mechanical Science and Technology》2012,26(12):3973-3979
In the present investigation, A356 alloy 5 wt% SiC composite is fabricated by electromagnetic stir casting process. An attempt has been made to investigate the effect of CNC lathe process parameters like cutting speed, depth of cut, and feed rate on surface roughness during machining of A356 alloy 5 wt% SiC particulate metal-matrix composites in dry condition. Response surface methodology (Box Behnken Method) is chosen to design the experiments. The results reveal that cutting speed increases surface roughness decreases, whereas depth of cut and feed increase surface roughness increase. Optimum values of speed (190 m/min), feed (0.14 mm/rev) and depth of cut (0.20 mm) during turning of A356 alloy 5 wt% SiC composites to minimize the surface roughness (3.15μm) have been find out. The mechanical properties of A356 alloy 5 wt% SiC were also analyzed. 相似文献
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Junfeng Xiang Siqin Pang Lijing Xie Xin Hu Song Peng Tao Wang 《The International Journal of Advanced Manufacturing Technology》2018,98(5-8):1237-1251
This paper focused on high-speed milling of Al6063 matrix composites reinforced with high-volume fraction of small-sized SiC particulates and provided systematic experimental study about cutting forces, thin-walled part deformation, surface integrity, and tool wear during high-speed end milling of 65% volume fraction SiCp/Al6063 (Al6063/SiCp/65p) composites in polycrystalline diamond (PCD) tooling. The machined surface morphologies reveal that the cutting mechanism of SiC particulates plays an important role in defect formation mechanisms on the machined surface. In high-speed end milling of Al6063/SiCp/65p composites, the cutting forces are influenced most considerably by axial depth of cut, and thus the axial depth of cut plays a dominant role in the thin-walled parts deformation. Increased milling speed within a certain range contributes to reducing surface roughness. The surface and sub-surface machined using high-speed milling suffered from less damage compared to low-speed milling. The milling speed influence on surface residual stress is associated with milling-induced heat and deformation. Micro-chipping, abrasive wear, graphitization, grain breaking off, and built-up edge are the dominated wear mechanism of PCD tools. Finally, a series of comparative experiments were performed to study the influence of tool nose radius, average diamond grain size, and machining parameters on PCD tool life. 相似文献
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Xiuli Geng Xuening Chu Zaifang Zhang 《The International Journal of Advanced Manufacturing Technology》2012,61(1-4):1-13
Many previous researches on high-speed machining have been conducted to pursue high machining efficiency and accuracy. In the present study, the characteristics of cutting forces, surface roughness, and chip formation obtained in high and ultra high-speed face milling of AISI H13 steel (46–47 HRC) are experimentally investigated. It is found that the ultra high cutting speed of 1,400?m/min can be considered as a critical value, at which relatively low mechanical load, good surface finish, and high machining efficiency are expected to arise at the same time. When the cutting speed adopted is below 1,400?m/min, the contribution order of the cutting parameters for surface roughness Ra is axial depth of cut, cutting speed, and feed rate. As the cutting speed surpasses 1,400?m/min, the order is cutting speed, feed rate, and axial depth of cut. The developing trend of the surface roughness obtained at different cutting speeds can be estimated by means of observing the variation of the chip shape and chip color. It is concluded that when low feed rate, low axial depth of cut, and cutting speed below 1,400?m/min are adopted, surface roughness Ra of the whole machined surface remains below 0.3?μm, while cutting speed above 1,400?m/min should be avoided even if the feed rate and axial depth of cut are low. 相似文献
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Effect of machining parameters on surface roughness and tool wear for 7075 Al alloy SiC composite 总被引:2,自引:2,他引:0
Rajesh Kumar Bhushan Sudhir Kumar S. Das 《The International Journal of Advanced Manufacturing Technology》2010,50(5-8):459-469
In the present study, an attempt has been made to investigate the influence of cutting speed, depth of cut, and feed rate on surface roughness during machining of 7075 Al alloy and 10 wt.% SiC particulate metal-matrix composites. The experiments were conducted on a CNC Turning Machine using tungsten carbide and polycrystalline diamond (PCD) inserts. Surface roughness of 7075Al alloy with 10 wt.% SiC composite during machining by tungsten carbide tool was found to be lower in the feed range of 0.1 to 0.3 mm/rev and depth of cut (DOC) range of 0.5 to 1.5 mm as compared to surface roughness at other process parameters considered. Above cutting speed of 220 m/min surface roughness of SiC composite during machining by PCD tool was less as compared to surface roughness at other values of cutting speed considered. Wear of tungsten carbide and PCD inserts was analyzed using a metallurgical microscope and scanning electron microscope. Flanks wear of carbide tool increased by a factor of 2.4 with the increase of cutting speed from 180 to 240 m/min at a feed of 0.1 mm/rev and a DOC of 0.5 mm. On the other hand, flanks wear of PCD insert increased by only a factor of 1.3 with the increase of cutting speed from 180 to 240 m/min at feed of 0.1 mm/rev and DOC 0.5 mm. 相似文献
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通过正交试验,研究了高速端铣加工中切削参数对表面粗糙度的影响。采用田口设计方法和响应曲面法构建了表面粗糙度预测模型,分析了主轴转速、进给量、切深对表面粗糙度的影响。结果显示,进给量对表面粗糙度的影响最显著,主轴转速次之,切深的影响不大。模型预测精度为99.84%,达到了较高的预测水平。 相似文献
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S. Jeyakumar K. Marimuthu T. Ramachandran 《Journal of Mechanical Science and Technology》2013,27(9):2813-2822
The results of mathematical modeling and the experimental investigation on the machinability of aluminium (Al6061) silicon carbide particulate (SiCp) metal matrix composite (MMC) during end milling process is analyzed. The machining was difficult to cut the material because of its hardness and wear resistance due to its abrasive nature of reinforcement element. The influence of machining parameters such as spindle speed, feed rate, depth of cut and nose radius on the cutting force has been investigated. The influence of the length of machining on the tool wear and the machining parameters on the surface finish criteria have been determined through the response surface methodology (RSM) prediction model. The prediction model is also used to determine the combined effect of machining parameters on the cutting force, tool wear and surface roughness. The results of the model were compared with the experimental results and found to be good agreement with them. The results of prediction model help in the selection of process parameters to reduce the cutting force, tool wear and surface roughness, which ensures quality of milling processes. 相似文献
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以螺旋铣孔工艺时域解析切削力建模、时域与频域切削过程动力学建模、切削颤振及切削稳定性建模为基础,研究了螺旋铣孔的切削参数工艺规划模型和方法。切削力模型同时考虑了刀具周向进给和轴向进给,沿刀具螺旋进给方向综合了侧刃和底刃的瞬时受力特性;动力学模型中同时包含了主轴自转和螺旋进给两种周期对系统动力学特性的影响,并分别建立了轴向切削稳定域和径向切削稳定域的预测模型,求解了相关工艺条件下的切削稳定域叶瓣图。在切削力和动力学模型基础之上,研究了包括轴向切削深度、径向切削深度、主轴转速、周向进给率、轴向进给率等切削工艺参数的多目标工艺参数规划方法。最后通过试验对所规划的工艺参数进行了验证,试验过程中未出现颤振现象,表面粗糙度、圆度、圆柱度可以达到镗孔工艺的加工精度。 相似文献
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V. Anandakrishnan A. Mahamani 《The International Journal of Advanced Manufacturing Technology》2011,55(1-4):65-73
This paper presents the results of an experimental investigation on the machinability of in situ Al-6061?CTiB2 metal matrix composite (MMC) prepared by flux-assisted synthesis. These composites were characterized by scanning electron microscopy, X-ray diffraction, and micro-hardness analysis. The influence of reinforcement ratio of 0, 3, 6, and 9?wt.% of TiB2 on machinability was examined. The effect of machinability parameters such as cutting speed, feed rate, and depth of cut on flank wear, cutting force and surface roughness were analyzed during turning operations. From the test results, we observe that higher TiB2 reinforcement ratio produces higher tool wear, surface roughness and minimizes the cutting forces. When machining the in situ MMC with high speed causes rapid tool wear due to generation of high temperature in the machining interface. The rate of flank wear, cutting force, and surface roughness are high when machining with a higher depth of cut. An increase in feed rate increases the flank wear, cutting force and surface roughness. 相似文献
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Enhancement and verification of a machined surface quality for glass milling operation using CBN grinding tool—Taguchi approach 总被引:3,自引:3,他引:0
M. Sayuti Ahmed A. D. Sarhan M. Fadzil M. Hamdi 《The International Journal of Advanced Manufacturing Technology》2012,60(9-12):939-950
Nowadays, the demand for high product quality focuses extensive attention to the quality of machined surface. The (CNC) milling machine facilities provides a wide variety of parameters set-up, making the machining process on the glass excellent in manufacturing complicated special products compared with other machining processes. However, the application of grinding process on the CNC milling machine could be an ideal solution to improve the product quality, but adopting the right machining parameters is required. Taguchi optimization method was used to estimate optimum machining parameters with standard orthogonal array L16 (44) to replace the conventional trial and error method as it is time-consuming. Moreover, analyses on surface roughness and cutting force are applied which are partial determinant of the quality of surface and cutting process. These analyses are conducted using signal to noise (S/N) response analysis and the analysis of variance (Pareto ANOVA) to determine which process parameters are statistically significant. In glass milling operation, several machining parameters are considered to be significant in affecting surface roughness and cutting forces. These parameters include the lubrication pressure, spindle speed, feed rate, and depth of cut as control factors. While, the lubrication direction is considered as a noise factor in the experiments. Finally, verification tests are carried out to investigate the improvement of the optimization. The results showed an improvement of 49.02% and 26.28% in the surface roughness and cutting force performance, respectively. 相似文献
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《Measurement》2016
Residual stresses are usually imposed on a machined component due to thermal and mechanical loading. Tensile residual stresses are detrimental as it could shorten the fatigue life of the component; meanwhile, compressive residual stresses are beneficial as it could prolong the fatigue life. Thermal and mechanical loading significantly affect the behavior of residual stress. Therefore, this research focused on the effects of lubricant and milling mode during end milling of S50C medium carbon steel. Numerical factors, namely, spindle speed, feed rate and depth of cut and categorical factors, namely, lubrication and milling mode is optimized using D-optimal experimentation. Mathematical model is developed for the prediction of residual stress, cutting force and surface roughness based on response surface methodology (RSM). Results show that minimum residual stress and cutting force can be achieved during up milling, by adopting the MQL-SiO2 nanolubrication system. Meanwhile, during down milling minimum residual stress and cutting force can be achieved with flood cutting. Moreover, minimum surface roughness can be attained during flood cutting in both up and down milling. The response surface plots indicate that the effect of spindle speed and feed rate is less significant at low depth of cut but this effect significantly increases the residual stress, cutting force and surface roughness as the depth of cut increases. 相似文献
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Empirical models and optimal cutting parameters for cutting forces and surface roughness in hard milling of AISI H13 steel 总被引:3,自引:3,他引:0
Tongchao Ding Song Zhang Yuanwei Wang Xiaoli Zhu 《The International Journal of Advanced Manufacturing Technology》2010,51(1-4):45-55
In the present research, an attempt has been made to experimentally investigate the effects of cutting parameters on cutting forces and surface roughness in hard milling of AISI H13 steel with coated carbide tools. Based on Taguchi’s method, four-factor (cutting speed, feed, radial depth of cut, and axial depth of cut) four-level orthogonal experiments were employed. Three cutting force components and roughness of machined surface were measured, and then range analysis and analysis of variance (ANOVA) are performed. It is found that the axial depth of cut and the feed are the two dominant factors affecting the cutting forces. The optimal cutting parameters for minimal cutting forces and surface roughness in the range of this experiment under these experimental conditions are searched. Two empirical models for cutting forces and surface roughness are established, and ANOVA indicates that a linear model best fits the variation of cutting forces while a quadratic model best describes the variation of surface roughness. Surface roughness under some cutting parameters is less than 0.25 μm, which shows that finish hard milling is an alternative to grinding process in die and mold industry. 相似文献
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A. I. Azmi R. J. T. Lin D. Bhattacharyya 《The International Journal of Advanced Manufacturing Technology》2013,64(1-4):247-261
Machining of composite materials is usually performed to achieve required geometrical shapes and dimensional tolerances. However, machinability evaluation of glass fibre-reinforced polymer (GFRP) composites in end milling has not yet received its due attention in the research community despite the extensive industrial use of this process. This work aims to elucidate the end milling machinability of GFRP composites with respect to surface roughness, tool life and machining forces. Experiments were conducted under different experimental parameters and their levels according to the Taguchi design of experiment method. Taguchi analysis combined with statistical analysis of variance (ANOVA) was performed to quantify the effects of spindle speed, feed rate and depth of cut on those characteristics. Multiple regression analysis (MRA) was also employed to establish parametric relationships between the experimental parameters and the machinability outputs. Results from ANOVA and MRA reveal that feed rate is the governing factor affecting all the machinability outputs. The calculated values from MRA have been found to be fairly close to experimental values in almost all cases. Validation tests under randomly selected machining conditions have further demonstrated the feasibility of the developed mathematical models with 8–12% error for tool life and machining forces predictions while >19% error for calculating the surface roughness. 相似文献
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This article is concerned with the cutting forces and surface integrity in high-speed side milling of Ti-6Al-4V titanium alloy. The experiments were conducted with coated carbide cutting tools under dry cutting conditions. The effects of cutting parameters on the cutting forces, tool wear and surface integrity (including surface roughness, microhardness and microstructure beneath the machined surface) were investigated. The velocity effects are focused on in the present study. The experimental results show that the cutting forces in three directions increase with cutting speed, feed per tooth and depth of cut (DoC). The widths of flank wear VB increases rapidly with the increasing cutting speed. The surface roughness initially decreases and presents a minimum value at the cutting speed 200 m/min, and then increases with the cutting speed. The microstructure beneath the machined surfaces had minimal or no obvious plastic deformation under the present milling conditions. Work hardening leads to an increment in micro-hardness on the top surface. Furthermore, the hardness of machined surface decreases with the increase of cutting speed and feed per tooth due to thermal softening effects. The results indicated that the cutting speed 200 m/min could be considered as a critical value at which both relatively low cutting forces and improved surface quality can be obtained. 相似文献