Advanced Materials Research Vol. 411

Abstract: As everyone knows, the temperature changes can cause the changes of mechanical geometric size. The thermal deformation obtained by traditional calculation formulas are approximate and linear, used in low precision requirement, however, if applied in high precision field, it is very limited. In this paper, by using the relations between crystal material line expansion coefficient and volume expansion coefficient, we will establish the thermal deformation mathematical model of cylindrical shaft and hole parts in the steady temperature, the model will consider the effects of the shape factors of parts on thermal deformation.

Abstract: An open motion control system of the engraving machine is developed. IPC and GE-300 motion control card constitute the main part of the hardware platform and windows system is used as the software development platform. Modularization programming technology is applied to design the software system of the machine to make programming easy. Based on the function and performance requirements of the engraving machine, the whole control system consists of initialization module, parameter setting module, coding module, manual processing module and inverter-motorized spindle module. The design philosophy and method of these modules are presented in this paper.

Abstract: The long spiral tube with its deep rifle groove make a long duration for Electrochemical Machining (ECM) and mass of floccule precipitate, esulting in bottleneck to maintain cleanliness of electrolyte in sedimentation basin at machining. The design scheme of duplex vertical flow electrolyte basin was proposed. The surface hydraulic power, available cubage, flooding area, sludge blanket level (SBH) and sludge tank height were calculated in terms of the electrical current, sinking speed of Fe(OH)3, flux of electrolyte. The streamline in the basin were simulated by COMSOL based elementary draft. The flow speed at intake of sludge blanket and the exit of clarified were analyzed with diameter of cone-meatus of center tube being altered and the space between it and baffle-board shifted, and the sedimentation basin is optimized.

Abstract: Electrochemical machining (ECM) was adopted to machine rifle lines with hard gun barrel material, increasing rifle in quantity, deep slot line as well as large spiral angle. Inner hole polishing cathode, rifle machining cathode and ECM device were designed to carry out the ECM experiment with the subject of gun barrel. The experiment results indicate that the machined workpiece coincides well with the blueprint.

Abstract: Electrochemical machining (ECM) molding was adopted to realize hot-forging die with high hardness, complex shape, high requirement for surface quality and sound demand effect. With the object of engine connecting rod hot-forging die, ECM cathode and device of hot-forging die main cavity and flash cavity were designed. The results indicate that ECM shaping can achieve hot-forging die machining with high efficiency, lowcost, no cutting stress and cavity primary shaping, and the machined hot-forging piece coincides well with the blueprint and obtains notable economic benefit.

Abstract: Deburring is a major bottleneck in manufacturing organizations. Burrs on the milled surface need to be removed and the surface quality must be maintained. Abrasive waterjet (AWJ) has been used in various operation for a wide range of materials. But no detailed investigations are known to be carried out on AWJ deburring. An orthogonal experiment is designed to investigate the effects of the AWJ parameters on burr removal and on surface quality. The results show that AWJ can remove the burrs from the stainless-steel specimens effectively under the condition of proper parameters, and the parameters such as abrasive grit size and stand-off distance are important not only for burr removal but also for surface quality, and slurry concentration is another important factor for surface quality.

Abstract: In the field of micromachining, micro electrical discharge machining (MEDM) is an important and perfect machining method for high rigid or high wearable materials, which is better than traditional methods of machining. MEDM technology is used to manufacture on-line electrodes and then minimum micro shafts with diameter of 15μm were made with these electrodes. A series of different micro-holes (e.g. Φ40μm、Φ50μm、Φ60μm) on pieces of molybdenum were manufactured with different parameters. Wastage of electrode rule was also studied.

Abstract: Electrochemical discharges machining (ECDM) is an unconventional technology able to machine several non-conductive materials like glass or some ceramics. ECDM technology remains an academic application and was never applied in industrial. The limit factors are highlighted. In order to improve removal rate (MRR) of Pyrex glass ECDM material and the surface quality, many promising measures such as ultrasonic vibration, abrasive, and side-insulated electrode are discussed.

Abstract: Most recently automobile pumps contain intersecting holes. However, there has been no efficient method for burr at intersecting holes. The theory of electrochemical deburring for high pressure pump body is firstly introduced. Then math model of ECM deburring and cathode model are built. Experiment results indicate that the technique can effectively remove the burrs of the hole and regulate the corner radius of injection holes. The smooth transition circle could be obtained around the conjunction of the hole, thus ECM deburring method can effiectively increase cleanliness of injector body and make the whole injector more stable.

Abstract: MRF (Magneto-rheological Finishing) is a kind of new technology which carries on fine polishing to the workpiece surface by using rheological property of MR fluids. A set of simple experimental equipment has been designed in this paper and magnet was selected for device forming magnetic filed. The main parameters of MRF which influence the surface quality of the metal material has been analyzed. The rule of the influence on surface roughness varying with several parameters has been summed up. The experiment results show that with the increase of magnetic field intensity, the value of surface roughness of workpiece decreases; the value increases with the increase of rotational velocity.The value of surface roughness of workpiece is in inverse proportion to the processing time. With the increase of time, the value of surface roughness of workpiece has been decreasing to basically stable after a certain amount of processing time.