Advances in Materials Manufacturing Science and Technology

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Authors: Bin Lin, Hong Tao Zhu, Hui Wu, Z.F. Wang, S.Y. Yu
Abstract: While be ground, ceramic is prone to engender surface/subsurface crack damage layer because of great grinding force and high brittle of the material. The crack damage layer was investigated in this research. In experiment, it is observed that the surface/subsurface crack damage layer consists of three kinds of cracks: surface micro-cracks, surface macro-cracks and subsurface crack system. To evaluate expediently the degree of damage to the machined components, the index of surface/subsurface crack damage - Dc, is defined.
Authors: Fang Hong Sun, Zhi Ming Zhang, H.S. Shen, Ming Chen
Abstract: Nanocrystalline diamond films were deposited on Co-cemented carbide substrates using CH4/H2/Ar gas mixture by hot filament chemical vapor deposition (HFCVD) technique. The evidence of nanocrystallinity, smoothness and purity was obtained by characterizing the sample with scanning electron microscopy (SEM), X-ray diffraction (XRD), Raman spectroscopy, atomic force microscopy (AFM), high-resolution transmission electron microscopy (HR-TEM) and selected-area electron diffraction (SAED). A new process was used to deposit composite diamond films by a two-step chemical vapor deposition procedure including first the deposition of the rough polycrystalline diamond and then the smooth fine-grained nanocrystalline diamond. The results show that the film consists of nanocrystalline diamond grains with sizes range from 20 to 80 nm. The Raman spectroscopy, XRD pattern, HR-TEM image and SAED pattern of the films indicate the presence of nanocrystalline diamond. Surface roughness is measured as Ra<100nm by AFM. Smooth nanocrystalline diamond layers can be deposited on conventional microcrystalline diamond layers using a two-step chemical vapor deposition by regulating the deposition parameters. These composite diamond films with the multiplayer (nanocrystalline/microcrystalline) structure have low surface roughness and high adhesive strength on WC-Co substrates. The diamond-coated tools and drawing dies with these composite coatings display excellent performances in the practical application.
Authors: Jian Hua Zhang, Sheng Feng Ren, Zong Wei Niu, Li Li, Min Gang Xu
Abstract: The material removal mechanism of ultrasonic machining sintered Nd-Fe-B magnetic materials was studied theoretically. The relation between critical load and central crack is given. In order to assure the material removal mode on material surface is brittle micro-fracture, the acting force of a single abrasive particle working on workpiece surface should be higher than the critical load. Experimental results show that there should be an optimal static load and an optimal abrasive size in certain ultrasonic machining system. The research results are helpful to guide practical production.
Authors: Ju Long Yuan, Fei Yan Lou, Zhi Wei Wang, M. Chang, W.P. Du, B.C. Tao
Abstract: STAVAX ESR(S-136)is a type of high stainless steel, used in precision mould widely . It has fine anticorrosion, polishing-alike, wearable,good process capacity and quench stability. To obtain the smooth surface of STAVAX ESR, the material removal mechanism in the paper is discussed. The experiment is processed on the ultra-precision plane polishing machine (Nanopoli-100). The experiment processes are as follows. Rough lapping and Ultra-precision lapping: the material of lapping pads is cast iron. #1000Al203 (10wt%) abrasive powders are used in rough lapping. Finally, surface roughness is 62nm. In ultra-precision lapping, abrasive powders are for #4000Al203(10wt%). Removal rate is 1nm with linear velocity 8.6m/min, pressure 3.65MPa. After 4000 rounds, surface roughness is 35nm.Ultra precision polishing: The super smooth surfaces of STAVAX ESR(S-136)with 5nm roughness have been obtained by adopting SiO2(> 30wt%) slurry and soft tin polisher in the experiment.
Authors: Chuan Zhen Huang, Lin He, Jun Wang, Han Lian Liu
Authors: Xi Peng Xu, Y.B. Hong, S. Chen
Abstract: An investigation is reported of the performance of diamond impregnated segments in three machining processes - circular sawing of granite with diamond segments, dressing of diamond segments with refractory bricks and surface grinding of diamond segments with an alumina wheel. Two kinds of segments were fabricated by incorporating diamonds (either coated or uncoated) into an iron-based bond matrix. Measurements were made of the horizontal and vertical force components in the machining processes. SEM was used to examine the diamond-matrix bonding states and the ground surfaces of the segments. The changes of forces and segment wear (weight loss and wear performance) were found to be basically consistent for the three machining processes.
Authors: Zhan Qiang Liu, Xiu Guang Peng, J.G. Liu
Abstract: Tool materials play one of the pivotal roles in the machining system. Tool materials must be carefully chosen in relation to the workpiece material to be machined, the tool life, the metal removal rate, the machining cost, and the required accuracy and finish. The advantages and decision-making processes of case-based reasoning (CBR) are described. The CBR system for tool material selection in high speed machining (HSM) is developed. The case expression and organization, searching, matching and constraint-based adaptation rules are presented. With combining the case-based reasoning strategy and constraint-based adaptation, the tool material can be properly selected on the basis of previously successful tool materials used in HSM operations, which is helpful to push the wide applications of HSM.
Authors: A. Hassan, Zheng Qiang Yao
Abstract: During excessive fluid application processing, fluid ends up on the floor, the workers, and the machine, entail serious techno-environmental and biological problems. Very little fluid enters the tool/part interface. Recently, this excess fluid has become another costly control problem. Chemicals of all types introduced into the atmosphere must also be reduced to an absolute minimum. In this paper, the technique of minimum quantity of lubrication (MQL), which is the pulverization of a minimum volume of oil in a flow of compressed air, has been studied in face mill Ti-6Al-4V titanium alloys as one alternative to the use of abundant cooling to suppress the cutting heat resulted from low thermal conductivity and the density of the workpiece material. The results showed that MQL of 125ml/h flow amount was found to be the optimum, and there is no significant difference in temperature between MQL of this flow and wet cooling when low cutting speeds used.
Authors: Zi Qiang Zhang, Qiu Sheng Yan, Zhi Dan Zheng, Shao Bo Chen
Abstract: Approximate Double Circular Arc Interpolated Method which was put forward by author, is different from other circular arc interpolated methods in demanding only the corner between normal directions of each circular arcs at intersection point are less than designated allowed value but not demanding contiguous circular arcs are tangent, and makes the calculating be predigested. In order to estimate error of the method, emulated calculating is carried out, namely the course of curve being obtained by reverse engineering is simulated in this paper. The results show: if space between measure points is about 0.1mm in curve being obtained by reverse engineering, then, the most departure of smoothing results from original curve is 0.552μm for the stated example. Influence of the error on NC machining is quite small, so it can meet the needs of NC machining.

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