Advanced Materials Research Vol. 426

Abstract: Though the high-speed cutting experimentation of high alloy antifriction cast iron, the materials performance and request on tools in cutting were analyzed. Though single-factor experimentation, the factors of affecting on cutting efficiency were discussed, such as tools materals, cutting speed, feed speed and cutting depth. The results show that the durability of PCBN tools is higher, but the durability of ceramics and tungsten-cobalt carbide tipped tools is low. The influence curve of cutting speed to machining efficiency is a part of parabola. And the influence curve of cutting depth to machining efficiency can be divided two parts of materials removal and tools wear. In the ensuring of technical requirements of work-piece machining. The high cutting efficiency can be obtained, when cutting speed vc=75~100m/min, feed speed f≤8mm and cutting depth ap =0.1~0.3mm.

Abstract: The key problems in 2D FEM simulation such as the establishment of finite element model, the initial stress loading, the distortion appraisal are solved and 2D FEM simulation model is built to analyze the milling distortion caused by the residual stress. The FEM model is verified by the elasticity theory. Some machining cases are simulated by using of the FEM model. The machining distortion caused by residual stress are analyzed and summarized using the simulation results.

Abstract: Crankshaft is widely used in the automotive industry, its quality has a direct impact on engine and vehicle performance. This paper the finite element analysis of crankshaft is discussed by using four different loads based on ANSYS workbench collaborative platform, thus the distribution of stress and strain is obtained and the relationships between arc radius and crankshaft stress is studied by changing the value of arc knuckle radius between the connecting rod journal and the crank at the junction of the transition, lastly the intrinsic mode of the crankshaft is analyzed. The results for the crankshaft provide a theoretical basis for designers and reference.

Abstract: For the purpose of investigating the surface defects on the machined surface in high speed milling of SiCp/Al Composites, the high speed milling experiments were performed on the precision milling machine (ops650).The machined surface was observed and measured by the OLS3000 Confocal Laser Scanning Microscope. The surface defects on the machined surface were classified and investigated. The surface defects mainly include grooves and holes due to the pulled-out particle. According to the geometrical characteristics of the pulled-out particles.

Abstract: Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal turning tests with coated carbide in higher speed scale was carried out on a CA6140 lathe. The experiential functions of tool life based on orthogonal experiment were developed. The tool wear morphologies were examined by scanning electron microscope (SEM) and energy disperse spectroscopy (EDS), adhesion, diffusion and micro-chipping were the major wear mechanisms of coated carbide tool. Finally, the cutting parameters of coated carbide tool in Ti6Al4V dry turning were optimized based on tool life-efficiency contour analysis, in same cutting efficiency, the lower cutting speed and larger depth of cut are the better selection in Ti6Al4V turning for coated carbide tool.

Abstract: An orthogonal test was carried out so as to analyze the cutting force in high speed rough milling with ball-end cutting tools. The wave form of the cutting force components was analyzed. The range analysis was performed to investigate the effect of cutting parameters on the cutting force. The analysis results show that the depth of cut and feed rate have the most significant effect on the resultant force. An empirical equation to describe the resultant cutting force was developed.

Abstract: The cutting zone temperature is the basic cutting process physical parameter, how to obtain it accurately is a problem over the years. In the paper, a method combined the artificial thermocouple method with thermal conduction reverse seeking method was proposed. The thermocouple can track the temperature history curve of the tool measured point. Then the tool and cutting process heat conduction models were built up in the ANSYS and AdvantEdge FEM respectively. According to the simulation results, the corresponding relationship between the rake face temperature and the measured point temperature and the shear slip face temperature can be solved. So the first and second deformation zone average temperature was obtained. Shown as the research results, the method proposed in the paper can obtain the small cutting zone temperature effectively. It provides technical support for the study of cutting process deformation and friction behavior.

Abstract: A new finite element model of BIG-PLUS tooling system are made, the BIG-PLUS tool holder and spindle deformation owing to centrifugal force generated by displacement, as well as different speed and clamping force of the radial displacement are analyzed and simulated. The results show that the radial clearance and deformation between spindle and tool holder can expand as the rotating speed increases, enhancing the clamping force and the shank of the spindle positioning accuracy and reliability of connection.

Abstract: This study using ultrasonic energy transmitted into the electrolyte to assist in discharging of electrolytic product out of the machining gap in the compound finishing processes of grinding and electropolishing on hole-wall surface beyond traditional process of holes machining instead of conventional hand or machine polishing. The compound processes of grinding and ultrasonic electro polishing just require a short time to make the hole-wall surface smooth and bright in the current study. The design polishing tool includes a grinding-tool and an electrode as a hole-wall surface finish improvement that goes beyond traditional rough boring. In the experiment, the polishing tool travels across the hole-wall surface with continuous or pulsed direct current. The experimental results show that the large supply of current rating is effectively to reach the amount of the material removal and is advantageous to the finishing processes. The average effect of the ultrasonic is better than the pulsed current while the machining time needs not to be prolonged by the off-time. The finish effect is better with a high rotational speed of the polishing tool because the dregs discharge of electrochemical finishing becomes easier and is also advantageous to the finish.

Abstract: A simplified model with periodicity space characteristics is presented to simulate interpenetrating network composites. The cutting process on this material is analysed by FEM. The results show that reinforced phase volume percentage(V%) has great effects on cutting deformation. When reinforced phase V% is larger, the cutting forces especially back force Fp fluctuate obviously which causes the whole manufacturing system to vibrate intensely.