Papers by Keyword: Surface Integrity

Abstract: The importance of the surface integrity in modern machining is represented. Based on the notion of the surface integrity that was put forward by Michael Field, a new method of surface integrity characterization is presented in this paper. This method consists of surface quality, surficial coat quality and the edge quality. Then an evaluation system of surface integrity based metrology is constructed and has been applied in a machining process of nickel-base alloy turbine disk. The manufacturing time decreased by approximately 10%. In all, this characterization and the evaluation system of surface integrity are rational and efficient. This work let us be capable of breaking through in the systematical evaluation of present machining surface.

Abstract: Titanium Alloy Ti-1023 is widely utilized in aerospace industry; the integrity of the parts machining surfaces is of critical importance for aerospace industry. Surface roughness, microstructure and microhardness variations were investigated on a CNC machining at different cutting speeds. Experiments results showed machined surface integrity of Ti-1023was sensitive to cutting speed. The roughness of machined surface raised with increase of the cutting speed from 40 m/min to 100 m/min, but decreased while the cutting speed increase from 100 m/min to 300 m/min. It can also draw the conclusion that no significant phase transformation, no obvious deformation and no white layer on subsurface microstructure can be observed. As for microhardness, it can also be seen that the machined workpiece surface was not seriously hardened, less than 35μm depth of work hardening at different cutting speed.

Abstract: Surface integrity is widely used for evaluating the quality of machined components. It has a set of various parameters which can be grouped as: (a) topography parameters (b) mechanical parameters and (c) metallurgical state. Many factors affect surface integrity including cutting parameters, tool geometry, material properties and vibrations. We can make prediction and optimization for surface integrity by taking advantages of these factors. This paper reviews previous studies and offers a comprehensive summary of surface integrity in the following order: introduction of surface integrity, main parameters of surface integrity, factors affecting surface integrity, prediction and optimization for surface integrity.

Abstract: Based on the experiments there was investigated the tool life of various kinds of cutting materials by hard machining. Taylor equations can be used for the cutting conditions setting. The measured values of surface roughness, residual stresses and microhardness show possibility of hard machining usage in practice. In case of the white layer zone appearance this needs to be eliminated by superfinishing. The ceramic and CBN wiper inserts are the objects of further research.

Abstract: Metal matrix composite is composite material that combines the metallic properties of matrix alloys and additional element to reinforce the product. This paper evaluates the machining performance of uncoated carbide and coated carbide in terms of surface integrity during end milling of LM6 aluminium MMC. The parameter of cutting speed, feed rate and axial depth of cut were kept constant at 3000 rpm spindle speed, 60 mm/min feed rate and 0.5 axial dept of cut. The radial depth of cut were varied from 0.01mm to 0.1 mm. The results indicated that uncoated carbide show the better performance in terms of surface roughness and surface profile, as compared to coated carbide. On the other hand, coated carbide cutting tools suffered with built-up-edge formation at the tool edge, hence caused shearing effect and deterioration at the tool-chip interface. This study is expected to provide understanding of machining metal matrix composites based materials.

Abstract: The high speed machining (HSM) of gray cast iron for manufacture mold and dies involve many different cutting tool from deep hole drills to smallest ball nose end mills [. Due to the demand of fast and high productivity, high speed machining (HSM) has been increasingly used to produce mold and dies that are mostly used in automotive industry especially for stamping dies components. The process of HSM sometimes combined together with manual polishing to enhance the die surface into fine mirror finish. Although the manual polishing strongly depends by experience and skill of workers, this technique is the preferable option for polishing of moulds and dies. However, such extensive manual polishing will provide some drawback because of many human factors such as pressure and technique of polishing individual person uses. Therefore, the application high speed machining in manufacturing is still demanding as it can improve surface finishing by reducing manual polishing, reportedly account for up to 30% of the total time [2].

Abstract: Increased attention on environmental and health impacts by industrial activities forces the manufacturing industry to reduce the mineral oil-based metalworking fluids as a cutting fluid. The advantages of using vegetable oil-based cutting fluids on tool wear and the cutting force have been reported in the literature, but those reporting the effects of their use on the surface finish of the workpiece are still lacking. This mini-review gives an overview of the influence of vegetable oil-based cutting fluids on surface integrity of steel during drilling process. Effect of the different cooling strategies on surface integrity is also presented.

Abstract: Surface integrity of machined component is of major importance for the reliability and safety requirements during in service especially for the aerospace applications. This paper presents an investigation on the effect of drill geometry on the surface integrity of drilled hole of Ti-6AL-4V during drilling operation. Drilling experiments were conducted under the MQL using a special vegetable oil known as Jatropha oil. Experimental results revealed that drill point angle and coolant-lubricant conditions significantly influence the surface integrity which include surface roughness, micorhardness and microstructure defects. The surface roughness decreased with greater drill point angle. The subsurface deformation layer thickness was approximately 9 - 15 μm from the top of the machined surface. Microhardness profiles of the last hole indicated that the subsurface deformation extend up to a 150 to 200 μm until it reaches to the average hardness.

Abstract: This paper via investigate the process of 9SiCr alloy steel in high efficiency deep grinding to find the rule between grinding wheel speed v_s depth of cut a_p and speed of table v_w with the grinding force and the surface quality. Intend to develop a suitable method of the grinding process of 9SiCr alloy steel in high efficiency deep grinding, to obtain high removal rate and good surface quality.

Abstract: The paper presents an experimental study on the relationship betweenprocess parametersand surface integrity of powder-metallurgy high-speed steel S390 in ultraprecision grinding. The optimal machining parametershave been obtained based on the Taguchi quality design method.The affected layerinduced by ultraprecision grinding has a uniform white layerand an inconspicuous dark layer; there are some carbides in the white layer of some samples; a compressive residual stress field exists on the ground surface. In addition, experiments confirm that lapping can remove the white layer effectively and increase the compressive residual stresses with a growth rate of 65%.The derived results satisfy the real requirements in practice.