Papers by Author: Ju Dong Liu

Abstract: According to the grind-hardening test and using the multiple linear regression analysis, the empirical formula of the tangential grinding force is established in this paper. Combined with the heat distribution coefficient formula of Rowe and Pettit, the thickness of the grind-hardening layer is predicted by using the finite element method under different grinding parameters. It draws the influence law of the grinding speed, cutting depth and feed rate to the thickness of the grind-hardening layer. It provided the basis to the drawing up, the application and the optimization of the grind-hardening process.

Abstract: Rotary ultrasonic machining (RUM) is considered as an effective machining method, which has been utilized to machine hard and brittle materials such as advanced ceramics. In order to improve the hole wall surface quality during RUM, it is important to wash away swarf in the gap between the tool and the workpiece as fast as possible. In this paper, a new machine process – intermittent rotary ultrasonic machining (IRUM) – is introduced for the first time. The cutting force, surface roughness and coolant flow rate in conventional rotary ultrasonic machining (CRUM) process and IRUM process are compared. It is found that compared with CRUM, the output coolant flow rate could be increased significantly by using the IRUM method. It is also found that the surface roughness of workpiece can be improved significantly in IRUM.

Abstract: Based on grind-hardening experiments, the two side-direction burrs were studied. Three main stages (burr generation, augmentation and formation) in the burr yielding process were clarified and the varying laws of burr morphologies and dimensions were systematically revealed. In turn raises, some new technologies, processes and methods of actively controlling burrs were put forward.

Abstract: Grind-hardening was done on Steel AISI 1066 with a conventional surface grinder and a corundum grinding wheel, and research was conducted to probe into structures and properties of the hardened layer under varied depth of cut and cooling conditions. Results show that the hardened layer do not change noticeably in their martensitic structures and micro-hardness, which is ranged between 810
870HV; But when the depth of cut increased or the dry grinding technique is adopted, the concentration of martensites and carbonides becomes lower, while the amount of residual austenites increases, and the completely hardened zone gets thicker. This conclusion serves as an experimental basis for the active control of properties of the grind-hardened layer of Steel AISI 1066.

Abstract: The structure and performance of the hardened layer in this paper has been researched by means of transverse feed grinding 40Cr steel on a plane grinding machine, the result shows that under the action of the grinding temperature field, there are different structural change rules and distributing characteristics of micro-hardness. Although there is always a softened band, which is made up of a transitional area and an unhardened area or a temper area in the hardened layer, the reasonable softened band is conducive to the improvement of wear-resistant quality of a hardened layer under the condition of oil lubrication.

Abstract: We had done the two-pass grind-hardening experiment on 40Cr steel using the conventional aluminum grinding wheel on a surface grinder, compared the structure and performance of the hardened layer of one-pass grinding with those of two-pass grinding and analyzed the forming mechanism of two-pass grinding hardened layers. The results show that there are a similar martensite structure and change rules of hardened layer of one-pass grinding and two-pass grinding in spite of the different of initial structures, for martensite has tempered by the action of the creep feed grinding temperature field. The depths of hardened layer, microhardness and wear resistance have further improved, but the maximal compressive residual stress and its influencing depth of hardened layer have decreased. The forming mechanism of the two-pass grinding hardened layer is the same as that of the grinding hardened layer of quenched steel.

Abstract: Grind-hardening was done on 65Mn steel with a conventional surface grinder and a corundum-grinding wheel. Research was conducted to probe into microstructures and properties of the hardened layer under varied depth of cut and cooling conditions. Results show that the hardened layer does not change noticeably in their martensitic structures and micro-hardness, which is ranged between 810-870HV. When the depth of cut increases or the dry grinding technique is adopted, the hardened layer becomes thicker accordingly. Under the condition of dry grinding with the depth of cut 1.0mm, the hardened layer depth reaches 2.0mm. It can find applications in grinding and metal surface modification field.