Advances in Materials Manufacturing Science and Technology

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Authors: H.X. Wang, Wen Jun Zong, Dan Li, Shen Dong
Abstract: In this paper, a new cutting force model is presented for diamond turning, and the ‘size effect’ is also integrated into this new model. Utilizing this new model, the effects of feed rate and depth of cut on cutting forces are analyzed, the specific law of cutting forces in micro thin-layer metal cutting is investigated at the same time. Through the detailed theoretical analysis and experimental validations, it is found that if the selected feed rate or depth of cut is less than a certain value, a particular phenomenon will appear, thus the thrust cutting force Fp is greater than the principal cutting force Fc, especially when the depth of cut or feed rate is of the same order as the rounded cutting edge radius. For the micro thin- layer metal cutting, the smaller the feed rate and depth of cut, the greater is the influence of these two parameters on cutting forces.
Authors: Sheng Sheng Zhang, Y.H. Cheng, L. Cheng
Abstract: The effects of work-piece heating temperature, holding time, and vacuity upon the quality of soldered fittings, when welding stainless heat exchanger (0cr17Ni12Mo2 plate) by vacuum brazing, are discussed in this paper. It also presents an optimized brazing procedure of welding heat exchanger. The processing property of soldered corrosion-resistant plate handled by the brazing procedure are discussed and optimized. Based on the analysis of samples taken from different sections of the welding seams, the paper studies the joint structure of brazing stainless steel.
Authors: Dun Wen Zuo, Wen Zhuang Lu, Xiang Feng Li, X.Q. Chu, Min Wang
Abstract: Few research works have been reported on hole making in EACVD thick diamond film, though many papers have been published on the preparation and smoothing of the film. In this paper, YAG laser and EDM were used to make holes in un-doped and Boron-doped diamond film respectively. Fundamental investigation was carried out on the effects of processing parameters on the holing efficiency and processed surface quality. The film surface was analyzed by means of Raman spectrum before and after holing. It is shown that YAG laser has a higher processing efficiency than EDM, but the latter can get a rounder hole.
Authors: D.L. Wang, T.H. Li, D.C. Kang
Abstract: With a significant progress achieved both in new kind of cutting tools and in machine tool design at high cutting speed, one of the weakest parts in the machining system is the toolholder/spindle interface system. In this paper the displacement of the 7/24 tapered tool interface and the HSK tool interface at high rotation speed is analyzed by means of the finite element method. The effects of the centrifugal force on the characteristics of the joints are investigated.
Authors: Yun Shan Wang, S. Fu, Jin Quan Xu, Can Lin Zhou, S.C. Si, C.Y. Gao
Abstract: Fourier transform profilometry in 3-D measurement based on wavelet digital filter is presented in this paper. Before phase demodulation, original modulated grating image is handled with wavelet transform in order to remove the background components and high frequency. This method resolves spectrum overlapping at some extent and reduces the requirement of low-pass filter.
Authors: Wen Jun Deng, Wei Xia, Zhao Yao Zhou, Wei Ping Chen, Yuan Yuan Li
Abstract: A three-dimensional coupled thermal-mechanical model of ball burnishing process is developed using commercial explicit finite element code MSC. Marc. The workpiece is modeled as being elastic-plastic, while its flowstress is taken as a function of strain, strain-rate, and temperature. Temperature-dependent material properties are also considered in this analysis. The burnishing ball is considered as rigid and only heat transfer analysis is carried out for it. In the zone of the workpiece and tool contact, the Coulomb friction is taken into account. Effects of ball burnishing parameters (burnishing force, feed rate, speed, ball diameter and number of tool passes) on residual stresses are analyzed. The results show that burnishing force, ball diameter, number of passes and burnishing feed have the most significant effect on the residual stresses. However, burnishing speed seems to just produce little effect on those. Larger burnishing force, larger number of passes, smaller ball diameter and small feed rate seem to be more effective in increasing in the maximum compressive residual stress and the depth of the layer at the compressive stress state.
Authors: Wei Xiao Tang, Xing Ai, H.Y. Wu, Song Zhang, H. Jiang
Abstract: Due to the complexity of high-speed milling process by high relative speed and interrupted cutting, the face milling cutters possess the multi-order modes and the vibrating displacements of the cutting edges under each modes affect adversely both the surface roughness and the life of machine/tool system worse than other structures. In order to improve the stability of milling process, this work focuses on the influence of the variables such as structure geometries and constraint conditions on the eigenfrequencies and modeshapes of cutter. As an example, the dynamic characteristics of several face cutters are analyzed and optimized by structural dynamic modification (SDM) techniques.
Authors: Jian Hua Wu, Zheng Qiang Yao, Y. Jin
Abstract: The surface roughness is evaluated by decomposing micro-errors from irregular surface image. The wave of surface is designated as signals including high-frequency, mid-frequency, and low-frequency signal, that denote roughness, waveness and the geometry shape error. Hilbert-Huang transform is a promising revolutionary technique for spectral data analysis, which is used to extract roughness from surface. It overcomes the imprecise result of the traditional surface roughness calculation and avoids the complication of the Wavelet analysis. Theory of Empirical Mode Decomposition (EMD) is given in the paper. This method is initially applied in picking up surface roughness, and it is proved to be of very high efficiency and simplicity.
Authors: A.K. Das
Abstract: Advancement and acceptance of Concurrent Engineering to speed up and improve product development process requires a systematic approach to the integrated, simultaneous design of products and their related processes, including manufacture and support [1] and Rapid Prototyping [2] is the one versatile tool that meet this requirement. Rapid Prototyping involves virtual prototyping and provides physical models as an end product. Traditionally initial industrial design concepts are shown as renderings or drawings, that show the look and feel of the product. The construction of mock up is followed after selection of a particular concept and these looks exactly like final product in true form, colour, texture etc. but without working internal components. With the advancement of CAD, 2 types of prototyping are in use in product design for modeling and simulating products performances. (a) Virtual prototyping using Analytical models (b) Physical prototyping making physical models These choices are influenced by variety of reasons. Physical prototypes are used for Communication purpose, Demonstration purpose, Scheduling /milestones, Feasibility study, Parametric modeling and Architectural interfacing. The above uses lead to a number of benefits such as insights into manufacturability and assemblability, accelerating of parallel activities and flexible product choices. In this paper, we are concerned from the point of view of an industrial designer for Integrated Product Development using concurrent engineering approach. Thus this paper highlights the benefits of Rapid Prototyping over conventional prototyping methods.
Authors: Yi Qi Zhou, Wei Xiao Tang, H. Zhang, B.C. Shi
Abstract: The remote virtual design system based on B/S framework is investigated in the paper. On reviewing the current virtual design system situation, the control system dynamics simulation is integrated into the virtual design system of roller gear cam mechanism. Simulink and Matlabserver are employed to realize the dynamics simulation for the system, and COM and VRML technologies are used to browse the virtual model on the network platform. The prototype system indicates that the system can serve as an effective tool for designing roller gear cam mechanism with the better properties of interactive dynamics performance design and expansion usage.

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