Advanced Materials Research Vol. 500

Abstract: Using the finite element analysis software ABAQUS, simulation experiments on physical nonlinearity, geometric nonlinear, nonlinear finite element, elastic-plastic in the cutting process are conducted, which realize the separation of chips and working piece combined with material failure criterion, shear failure, adaptive grid technique in ABAQUS. Meanwhile, the stress field, strain and temperature field and cutting force in the cutting simulation are obtained consistent with cutting theory.

Abstract: Based on the field research, we found that in the course of high-speed face milling aluminum, Cutters components prone to deformation as the role of load such as Centrifugal force, Cutting force and Preload. The deformation will directly affect the the dynamic performance of the cutter. So its necessary to reveal the dynamic response of the deformation cutter. We base on the Dynamic model and the modal analysis model, Obtained the deformation cutters dynamic simulation which the cutters deformation is come from the ANSYS. At last we got the method of identifying cutters deflection deformation by vibration signal. With the method we can effectively identifying milling distortion In the cutting process.

Abstract: Adopted the cutting-contact model of high speed ball-end milling hardened steel surfaces, researched distribution characteristics of cutting-contact stress; by researching the influence of the distribution of this stress on cutter wear, clarified the influence theory of milling pattern and cutting parameters on initial wear of milling cutter. By using the method of climbing, conventional milling alternating and changing cutting parameters, verified the influence of milling pattern and cutting parameters on initial wear pattern. The result showed that, initial wear mechanism of high speed milling hardened steel is an interaction of multiple wear mechanisms under the effect of friction and alternating pressure stress, by using conventional milling can significantly reduce concave curvature radius of hardened steel, the contact stress of blade area and front, rear flank, inhibit crushing and wear rate of the milling cutter surfaces. Under this condition, by increasing rotation speed and reducing the feed per blade, will further increase the strength of this effect, and achieve the purpose of reducing the initial wear, inhibiting the wear rate and extending the cutters life.

Abstract: The article is about the safety for high speed milling tools between macroscopic and mesoscale, making some analysis about the relationship between damage of cutting tools and its components and mesoscale movement, the damage of cutting tools and its components is known. With the boundary conditions of material force damage, using the material design software named MAPS to do molecular dynamics simulation, the simulation is about mesoscale state in different stress, Make sure the various mesoscale movement on stress response rate, the model of intrinsic/extrinsic about the safety for high speed milling tools on a mesoscale is established. Clear the value of intrinsic/extrinsic parameters and mesoscale movement on stress response rate. The regular pattern between damage of cutting tools and its components and mesoscale movement, which could help us to design tools, choose materials of tools and determine cutting parameters.

Abstract: The problem of Sticking Failure of cutting tool is serious for cutting stainless steel 1Cr18Ni9Ti, on the basis of the Sticking Failure orthogonal experiment of YG8, it researches the range of temperature for Sticking Failure, chooses the best cutting parameters, and researches the effect for Sticking Failure, which provides the academic basis for the study of criterion of the mechanism of Sticking Failure.

Abstract: Through the analysis on damaged tool in sticking failure experiment by cutting austenitic stainless steel (1Cr18Ni9Ti) with scanning electron microscopy (SME), found that there are micro cracks existent on rake face near the tip of the cutting tool, through the research of the emergence, development and distribution direction of the crack, the direct reason for tool breakage is the crack being out of control. Combining the study of cutting tool element density change in cutting zone and grooving wear on rake face, this paper analyzed the cause of the binding between chip and tool and the influence factors of sticking failure during the cutting process.

Abstract: This paper obtained the mechanical properties of 1Cr18Ni9Ti by the static tensile test, got the corresponding relationship between the 1Cr18Ni9Ti coefficient of linear expansion, thermal conductivity and temperature changes, and simulated the process of 1Cr18Ni9Ti cutting with the finite element simulation software, then analysised the reason why the deviation of the finite element simulation results and measured data increased with the cutting speed improved. These studies provide some important references for the finite element simulation and revealing the tool wear and breakage mechanism.

Abstract: This article take the Dongan 465Q non-supercharged engine as the research object, the simulation model is built by GT-POWER and the corresponding test bench is set up. The simulation error is less than 3%, which indicates that the parameters of this model is correct, and can be used for further study of the gasoline engine. The supercharger, Garrett GT12, is selected by the matching calculation. The non-supercharged 465Q engine is modified as a turbocharged engine. The test results show that the power and the fuel consumption of the turbocharged engine is improved obviously, whose power is increased by 48% and fuel consumption is reduced by 4%.

Abstract: Due to the superior mechanical and thermal properties of SiCp/Al composites, their poor machinability has been the main deterrent to their substitution for metal parts. Machining of SiCp/Al composites has been considerably difficult because the extremely abrasive nature of SiC reinforcements causes rapid tool wear. In this paper, an experiment was carried out to investigate the influence of the cutting speed, cutting depth and tool rake angle on cutting force during orthogonal machining of SiCp/Al composites. The results indicate that the cutting depth is one of the main cutting parameters that affect the cutting force, while the cutting speed and tool rake angle have no significant effects on the cutting force.

Abstract: Micro abrasive air jet (MAAJ) cutting is a promising technology for the fabrication of three-dimensional microstructures in hard and brittle materials. In this paper, a study on the cross-sectional shape of the kerf cut with MAAJ is presented. It shows that the machining depth and slope of the sidewall increase with an increase in air pressure, abrasive flow rate and jet incidence angle, while decrease with an increase in nozzle traverse speed. Using a dimensional analysis technique, predictive model for cross-sectional profile is developed. The research results may be meaningful to the highly precision three-dimensional micro-structural cutting.