Materials Science Forum Vol. 723

Abstract: Tool selection is one of the most significant process considerations when deciding how a machined product will be manufactured. The tool selection activity is rooted in feature geometry but it also has a direct impact on machinability and machine tool performance. This paper presents a computer-based intelligent system for the automatic selection of cutting processes and tools. The main objective of the research work was to develop a procedure for the selection of cutting tools and cutting parameters. This will help the designers and manufacturing planners to select an optimal set of cutting tools and cutting conditions for different material properties and to give users alternatives on how to reduce cost and time.

Abstract: Currently biomimetic tribology study shows that high performance surface texture can achieve good friction, anti-adhesion and improve the wear resistance, which brings a new research direction for tool antifriction technology. The orthogonal cutting tests of surface micro-groove cutting tool in machining titanium alloy were presented. Different types of micro-grooves were made using laser in the rake face of uncoated tungsten carbide cutting inserts. Dry with no lubricant and minimal quantity lubricant (MQL) were used as lubrication conditions. Cutting force and cutting temperature were measured and compared. It was found that under MQL condition the surface micro-grooves could effectively improve the friction status between the tool and chip, thereby reducing cutting force and cutting temperature, and also reduce cutting temperature under no lubricant condition. The micro-grooves paralleling with cutting edge had the best effect in three types of micro-grooves.

Abstract: Austenitic stainless steel has poor cutting performance, especially when the inappropriate choice of tool materials and cutting parameters, cutting tool life will be shortened and the quality of machined surface is poor. In this paper, 0Cr18Ni9 stainless steel dry cutting tests had been done with nano-TiAlN coated carbide blade YGB202, the relationship between tool life and cutting speed, tool wear mechanism had been analyzed. In order to improve the processing efficiency and tool life, process parameters were optimized.

Abstract: The hazards of HSK toolholders caused by unbalance vibration are described The vibration information can be more accurately extracted by choosing the appropriate method of measuring unbalance and using FFT transform to reconstruct wavelet signal. Finally, the HSK tool holders unbalance measurement software module diagram are shown. This way can be a good basis for scientific research and the development of the HSK integrated measurement system.

Abstract: The design concept of functionally graded materials was first introduced into the development of self-lubricating ceramic cutting tool materials. An Al₂O₃/TiC/CaF₂ graded self-lubricating ceramic cutting tool material was designed and fabricated. Mechanical properties were evaluated by comparing with those of Al₂O₃/TiC/CaF₂ homogeneous self-lubricating ceramic cutting tool material. The results showed that the Al₂O₃/TiC/CaF₂ graded self-lubricating ceramic cutting tool material had superior performance to the counterpart. Graded self-lubricating ceramic cutting tool materials are bound to have promising prospect in the field of high speed dry machining.

Abstract: On the basis of modal analysis theory, a free modal test and a work modal test of the HSK tool holder and thin-disk cutters with the vibration measuring method were carried out. The modal parameters such as inherent frequency, damping ratio and modal shapes were gained. These modal parameters were compared with modal parameters, which were gained with the finite element method. The results verified whether the construction of the finite element modal was reasonable or not, and provided technical help for exploring the dynamic characteristics and structural optimization of HSK tool system, making the full use of HSK tool holder in high- speed machining.

Abstract: Unbalance vibration is introduced. The reasons of HSK shank unbalance and the features of vibration signal are analyzed. The method of signal essing is described. Finally, transformation and reconstruction of the vibration signal are studied by wavelet theory. HSK shank’s vibration is more accurately extracted. This way can be a good basis for scientific research and the development of the HSK integrated measurement system.

Abstract: The principle of the HSK shrink toolholder is expanding with heat and contracting with cold. The heat performance of HSK is analyzed. Firstly, the induction heating performance is studied by using electromagnetism-thermal-structure FEA in ANSYS software and experiment, the optimal temperature of HSK shrink toolholder is got. Secondly, thermal fatigue and calculation of the fatigue life is analyzed by using thermal-stress in ANSYS software and Coffin-Manson formula. The loads applied on the FEA model are temperature during the cycle of heating and cooling.

Abstract: Boron-doped diamond films are deposited on cobalt cemented tungsten carbide (WC-Co) printed circuit board (PCB) milling tools using hot filament chemical vapor deposition (HFCVD) method. Trimethyl borate is used as boron source. Scanning electron microscope (SEM) and Raman spectroscopy are used to characterize the as-deposited diamond films. To evaluate the cutting performances of as-fabricated boron-doped diamond (BDD) coated milling tools, milling tests are conducted using copper-clad laminate（CCL）as the workpiece material, compared with microcrystalline diamond (MCD) coated and uncoated milling tools. The experimental results show that the BDD films have strong adhesive strength to the substrate and can protect the cutting edge from rapid wearing out. The results suggest that depositing BDD coating on WC-Co milling tools is a viable way to improve their cutting performances in machining of PCB materials.

Abstract: An open architecture NC system of flame cutting machine applied in auto white-body welding line manufacturing is developed in this paper. The general planning and the composition of the NC system is presented based on IPC and Trio MC206 motion card, the hardware and software of the control system are designed detailedly. IPC management software developed by using C# language in Visual Studio 2008 and rock-bottom control program of Trio control card developed in Motion Perfect2 are realized. The application results show that the NC system of flame cutting machine is reliable and stable which can meet the requirements of auto white-body manufacturing perfectly.